High resolution organic light-emitting diode devices, displays, and related method

ABSTRACT

In accordance with an exemplary embodiment of the present disclosure, a method of manufacturing an organic light-emissive display can be provided. A plurality of electrodes can be provided on a substrate. A first hole conducting layer can be deposited via inkjet printing over the plurality of electrodes on the substrate. A liquid affinity property of selected surface portions of the first hole conducting layer can be altered to define emissive layer confinement regions. Each emissive layer confinement region can have a portion that respectively corresponds to each of the plurality of electrodes provided on the substrate. An organic light-emissive layer can be deposited via inkjet printing within each emissive layer confinement region.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/254,562, filed Sep. 1, 2016. U.S. patent application Ser. No.15/254,562 is a divisional of U.S. patent application Ser. No.14/156,188, filed Jan. 15, 2014, which issued Sep. 13, 2016 as U.S. Pat.No. 9,444,050. U.S. Pat. No. 9,444,050. U.S. claims the benefit ofProvisional Patent Application No. 61/753,713, filed Jan. 17, 2013. U.S.Pat. No. 9,444,050 is a continuation-in-part of U.S. patent applicationSer. No. 14/030,776, filed Sep. 18, 2013, which claims the benefit ofU.S. Provisional Patent Application No. 61/753,692, filed Jan. 17, 2013.U.S. Each of the aforementioned applications is incorporated byreference herein in its entirety.

TECHNICAL FIELD

Aspects of the present disclosure generally relate to electronicdisplays and methods for making electronic displays. More particularly,aspects of the present disclosure relate to depositing and confiningactive organic light emitting diode (OLED) display materials on asubstrate so as to fabricate an OLED display.

INTRODUCTION

The section headings used herein are for organizational purposes onlyand are not to be construed as limiting the subject matter described inany way.

Electronic displays are present in many differing kinds of electronicequipment such as, for example, television screens, computer monitors,cell phones, smart phones, tablets, handheld game consoles, etc. Onetype of electronic display relies on organic light emitting diode (OLED)technology. OLED technology utilizes an organic light-emissive layersandwiched between two electrodes disposed on a substrate. A voltage canbe applied across the electrodes causing charge carriers to be excitedand injected into the organic light-emissive layer. Light emission canoccur through photoemission as the charge carriers relax back to normalenergy states. OLED technology can provide displays with a relativelyhigh contrast ratio because each pixel can be individually addressed toproduce light emission only within the addressed pixel. OLED displaysalso can offer a wide viewing angle due to the emissive nature of thepixels. Power efficiency of an OLED display can be improved over otherdisplay technologies because an OLED pixel only consumes power whendirectly driven. Additionally, the panels that are produced can be muchthinner than in other display technologies due to the light-generatingnature of the technology eliminating the need for light sources withinthe display itself and the thin device structure. OLED displays also canbe fabricated to be flexible and bendable due to the compliant nature ofthe active OLED layers.

Inkjet printing is a technique that can be utilized in OLEDmanufacturing, and may reduce manufacturing cost. Inkjet printing usesdroplets of ink containing OLED layer material and one or more carrierliquids ejected from a nozzle at a high speed to produce one or moreactive OLED layers including, for example a hole injection layer, a holetransport layer, an electron blocking layer, an organic light emissivelayer, an electron transport layer, an electron injecting layer, and/ora hole blocking layer.

Confinement structures such as banks are typically provided on thesubstrate to define confinement wells where each confinement well can beassociated with one or more sub-pixels, for example sub-pixels ofdiffering colors or wavelength emissions. The confinement wells canprevent the deposited active OLED material(s) from spreading betweenadjacent sub-pixels. Inkjet printing methods can require substantialprecision. In particular, as pixel density increases and/or as displaysizes decrease, the confinement areas of the confinement wells arereduced and small errors in droplet placement can cause the droplet tobe deposited outside the intended well. Moreover, droplet volumes can betoo large with respect to the confinement well and droplets canundesirably spill over into adjacent sub-pixels.

In addition, non-uniformities in the active OLED layers can form at theedges in contact with confinement structures due to film dryingimperfections. Film drying imperfections can be caused by themanufacturing process and/or the materials used for the confinementstructures. As the confinement well area is reduced, thenon-uniformities of the layers can encroach on the active emission areaof the pixel creating undesirable visual artifacts in the light emissionfrom the pixel caused by the non-uniformities. The resulting relativereduction in layer uniformity associated with the active emission areaof the pixel also can negatively impact efficiency of the displaybecause electrodes must be driven harder to achieve a relativebrightness output. When the materials used for the confinementstructures influence the film drying imperfections, the active OLEDmaterial may need to be reformulated.

Moreover, a reduction in the ratio of the active area to the total area,where the total area includes both the active and non-active areas ofeach pixel due to the confinement structures and the non-uniform activeemission area, can reduce the lifetime of the display. This is becauseeach electrode has to be driven using more current to achieve equivalentdisplay brightness levels and using more current to drive each electrodeis known to reduce the pixel lifetime. The ratio of the active area tothe total area is referred to as “fill factor.”

Although traditional inkjet methods address some of the challengesassociated with OLED display manufacturing, there exists a continuedneed for improvement. For example, there exists a continued need toimprove droplet deposition precision in the manufacturing of OLEDs, inparticular for OLED displays having a high resolution (i.e., high pixeldensity). Moreover, there exists a need to reduce undesirable visualartifacts created by the deposition of the organic light-emissive layerin high resolution displays. There also exists a need to improve thedevice lifetime by increasing the fill factor of each pixel. Further,there exists a need for improvement in using and manufacturing OLEDdisplays in high resolution display applications, including but notlimited to, for example, high resolution mobile phones and tabletcomputers, which present challenges in achieving acceptable resolution,power efficiency, display lifetime, and manufacturing cost.

SUMMARY

The present disclosure may solve one or more of the above-mentionedproblems and/or achieve one or more of the above-mentioned desirablefeatures. Other features and/or advantages may become apparent from thedescription which follows.

In accordance with an exemplary embodiment of the present disclosure, amethod of manufacturing an organic light-emissive display can beprovided. A plurality of electrodes can be provided on a substrate. Afirst hole conducting layer can be deposited via inkjet printing overthe plurality of electrodes on the substrate. A liquid affinity propertyof selected surface portions of the first hole conducting layer can bealtered to define emissive layer confinement regions. Each emissivelayer confinement region can have a portion that respectivelycorresponds to each of the plurality of electrodes provided on thesubstrate. An organic light-emissive layer can be deposited via inkjetprinting within each emissive layer confinement region.

In accordance with another exemplary embodiment of the presentdisclosure, an organic light-emissive display can be provided. Aplurality of electrodes can be disposed on a substrate. The plurality ofelectrodes can be arranged in an array configuration. A confinementstructure can be disposed on the substrate. The confinement structurecan surround the plurality of electrodes. A first hole conducting layercan be disposed over the plurality of electrodes within the confinementstructure. A liquid affinity property of surface portions of the firsthole conducting layer can be altered to define emissive layerconfinement regions within the first hole conducting layer. An organiclight-emissive layer can be disposed within each emissive layerconfinement region.

In another exemplary embodiment of the present disclosure, an organiclight-emissive display can be made by a process as provided. A substratecomprising a plurality of electrodes disposed on the substrate can beprovided. At least one hole conducting layer can be deposited, viainkjet printing, over the plurality of electrodes on the substrate. Aliquid affinity property of select portions of at least one holeconducting layer can be altered to define emissive layer confinementregions on a surface of the at least one hole conducting layer. Anorganic light-emissive layer can be deposited via inkjet printing withineach emissive layer confinement region defined within the at least onehole conducting layer.

Additional objects and advantages will be set forth in part in thedescription which follows, and in part will be obvious from thedescription, or may be learned by practice of the present teachings. Atleast some of the objects and advantages of the present disclosure maybe realized and attained by means of the elements and combinationsparticularly pointed out in the appended claims.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory onlyand are not restrictive of the claims. It should be understood thatvarious embodiments of the invention, in its broadest sense, could bepracticed without having one or more features of these exemplary aspectsand embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate some exemplary embodiments of thepresent disclosure together with the description, serve to explaincertain principles. In the drawings,

FIG. 1 is a partial plan view of a conventional pixel arrangement.

FIG. 2 is a partial plan view of an exemplary pixel arrangement inaccordance with the present disclosure;

FIG. 3A is a cross-sectional view of a confinement well along line 3A-3Ain FIG. 1 of an exemplary embodiment in accordance with the presentdisclosure;

FIG. 3B is a cross-sectional view of a plurality of confinement wellsalong line 3B-3B in FIG. 1 of an exemplary embodiment in accordance withthe present disclosure;

FIG. 4 is a cross-sectional view similar to the view of FIG. 3A ofanother exemplary embodiment of a confinement well in accordance withthe present disclosure;

FIG. 5A is a cross-sectional view similar to the view of FIG. 3A ofanother exemplary embodiment of a confinement well in accordance withthe present disclosure;

FIG. 5B is a cross-sectional view similar to the view of FIG. 3B ofanother embodiment of a confinement well in accordance with the presentdisclosure;

FIG. 6 is a cross-sectional view of yet another exemplary embodiment ofa confinement well in accordance with the present disclosure;

FIG. 7 is a cross-sectional view of yet another exemplary embodiment ofa confinement well in accordance with the present disclosure;

FIGS. 8-11 are cross-sectional views of another exemplary embodiment ofa confinement well and exemplary steps for creating an OLED display inaccordance with the present disclosure;

FIGS. 12-19 are partial plan views of various exemplary pixelarrangements in accordance with the present disclosure;

FIG. 20 is a front view of an exemplary apparatus including anelectronic display in accordance with the present disclosure;

FIG. 21 is a front view of another exemplary apparatus including anelectronic display in accordance with the present disclosure;

FIG. 22 is a plan view of an exemplary embodiment of an OLED display inaccordance with the present disclosure;

FIG. 23 is a cross-sectional view of the OLED along line 23-23 in FIG.22 of an exemplary embodiment in accordance with the present disclosure;

FIGS. 24-29 are cross-sectional views of another exemplary embodiment ofan OLED display, depicting exemplary steps for creating an OLED displayin accordance with the present disclosure;

FIG. 30 is the cross-section of the magnified portion M illustrated inFIG. 29;

FIG. 31 is a plan view of the magnified portion M illustrated in FIG.29;

FIG. 32 is another plan view of a magnified portion of an anotherexemplary embodiment of an OLED display in accordance with the presentdisclosure;

FIG. 33 is an alternative exemplary embodiment of a cross-section of themagnified portion M illustrated in FIG. 29;

FIGS. 34-36 are cross-sectional views of another exemplary embodiment ofan OLED display, depicting exemplary steps for creating an OLED displayin accordance with the present disclosure;

FIG. 37 is another alternative exemplary embodiment of a cross-sectionof the magnified portion M illustrated in FIG. 29 in accordance with thepresent disclosure;

FIGS. 38 and 39 are cross-sectional views of another exemplaryembodiment of an OLED display, depicting exemplary steps for creating anOLED display in accordance with the present disclosure;

FIG. 40 is the cross-section of the magnified portion illustrated inFIG. 39 of another exemplary embodiment of an OLED display in accordancewith the present disclosure; and

FIG. 41 is a partial plan view of an exemplary pixel arrangement inaccordance with the present disclosure.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

Reference will now be made in detail to various exemplary embodiments ofthe present disclosure, examples of which are illustrated in theaccompanying drawings. Wherever possible, the same reference numberswill be used throughout the drawings to refer to the same or like parts.

For the purposes of this specification and appended claims, unlessotherwise indicated, all numbers expressing quantities, percentages, orproportions, and other numerical values used in the specification andclaims, are to be understood as being modified in all instances by theterm “about,” to the extent they are not already so modified.Accordingly, unless indicated to the contrary, the numerical parametersset forth in the following specification and attached claims areapproximations that may vary depending upon the desired propertiessought to be obtained. At the very least, and not as an attempt to limitthe application of the doctrine of equivalents to the scope of theclaims, each numerical parameter should at least be construed in lightof the number of reported significant digits and by applying ordinaryrounding techniques.

It is noted that, as used in this specification and the appended claims,the singular forms “a,” “an,” and “the,” and any singular use of anyword, include plural referents unless expressly and unequivocallylimited to one referent. As used herein, the term “include” and itsgrammatical variants are intended to be non-limiting, such thatrecitation of items in a list is not to the exclusion of other likeitems that can be substituted or added to the listed items.

Further, this description's terminology is not intended to limit theinvention. For example, spatially relative terms—such as “beneath”,“below”, “lower”, “top”, “bottom”, “above”, “upper”, “horizontal”,“vertical”, and the like—may be used to describe one element's orfeature's relationship to another element or feature as illustrated inthe figures. These spatially relative terms are intended to encompassdiffering positions (i.e., locations) and orientations (i.e., rotationalplacements) of a device in use or operation in addition to the positionand orientation shown in the figures. For example, if a device in thefigures is turned over, elements described as “below” or “beneath” otherelements or features would then be “above” or “over” the other elementsor features. Thus, the exemplary term “below” can encompass bothpositions and orientations of above and below depending on the overallorientation of the device. A device may be otherwise oriented (rotated90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly.

As used herein, “pixel” is intended to mean the smallest functionallycomplete and repeating unit of a light emitting pixel array. The term“sub-pixel” is intended to mean a portion of a pixel that makes up adiscrete light emitting part of the pixel, but not necessarily all ofthe light emitting parts. For example, in a full color display, a pixelcan include three primary color sub-pixels such as red, green, and blue.In a monochrome display, the terms sub-pixel and pixel are equivalent,and may be used interchangeably.

The term “coupled” when used to refer to electronic components isintended to mean a connection, linking, or association of two or moreelectronic components, circuits, systems, or any combination of: (1) atleast one electronic component, (2) at least one circuit, or (3) atleast one system in such a way that a signal (e.g. current, voltage, oroptical signal) can be transferred from one to another. The connection,linking, or association of two or more electronic components, circuits,or systems can be direct; alternatively intermediary connections,linkings, or associations may be present, and thus coupling does notnecessarily require a physical connection.

One of ordinary skill in the art would generally accept the term “highresolution” to mean a resolution greater than 100 pixels per inch (ppi)where 300 ppi can sometimes be referred to as very high resolution. Oneof ordinary skill in the art would also recognize that pixel densitydoes not directly correlate to the size of the display. Variousexemplary embodiments disclosed herein can be used to achieve highresolution in small and large display sizes. For example, displayshaving a size of about 3 inches to about 11 inches can be implemented ashigh resolution displays. Moreover, displays having larger sizes, suchas television displays up to 55″ and beyond, can also be used withvarious exemplary embodiments described herein to achieve highresolution displays.

As used herein, a layer or structure being “on” a surface includes boththe case where the layer is directly adjacent to and in direct contactwith the surface over which it is formed and the case where there areintervening layers or structures between the layer or structure beingformed over the surface.

The term “reactive surface-active material” is intended to mean amaterial that can be used to modify at least one property of a layer ofthe OLED display when applied to a surface of the layer duringmanufacturing of the display. For example, when the reactivesurface-active material is processed such as exposing the material toradiation, at least one of a physical, chemical, and/or electricalproperty of the layer associated with the reactive surface-activematerial can be altered. In an exemplary embodiment, the terms“liquid-affinity region” and “liquid-repelling region” can be used torefer to the resulting relative surface energies produced on the surfaceof the layer associated with the reactive surface-active material beforeand/or after the reactive surface-active material is processed. Forexample, “liquid-affinity region” can be used to refer to a portion ofthe surface of the layer that has surface energy that tends to attractliquid such that a liquid-affinity region portion can be, for example,relatively hydrophilic when the liquid is a water based fluid. The term“liquid-repelling region” can be used to refer to a portion of thesurface of the layer that has a surface energy tending to repel liquidsuch that a liquid-repelling portion can be, for example, relativelyhydrophobic when the liquid is a water based fluid. However, aliquid-repelling portion does not have to be completely phobic to afluid. In other words, a liquid-repelling portion does not have asurface energy that completely repels a fluid but instead, when aliquid-repelling portion is adjacent to a liquid-affinity region liquidwill tend to migrate away from the liquid-repelling region and beattracted to the liquid-affinity region.

Various factors can influence deposition precision of organiclight-emissive layers in OLED display manufacturing techniques. Suchfactors include for example, display resolution, droplet size, targetdroplet area, droplet placement error, fluid properties (e.g., surfacetension, viscosity, boiling point) associated with the OLED layermaterial (e.g., active OLED materials) inks, which are comprised of acombination of OLED layer material and one or more carrier fluids, andthe velocity at which the droplets are deposited. As display resolutionsincrease, for example greater than 100 ppi, or for example greater than300 ppi, various issues arise in using inkjet printing techniques forOLED display manufacturing. High precision inkjet heads used in theconventional printing techniques can produce droplet sizes ranging fromabout 1 picoliter (pL) to about 50 picoliters (pL), with about 10 pLbeing a relatively common size for high precision inkjet printingapplications. Droplet placement accuracy of a conventional inkjetprinting system is approximately ±10 μm. In various exemplaryembodiments, confinement wells can be provided on the substrate tocompensate for droplet placement errors. A confinement well can be astructure that prevents OLED material from migrating beyond a desiredsub-pixel area. To ensure that a droplet accurately lands at a desiredlocation on a substrate, such as entirely within a confinement well,various exemplary embodiments configure the confinement well to be aswide as the droplet diameter plus twice the droplet placement error ofthe system. For example, the diameter of a 10 pL droplet is about 25 μmand thus the preceding parameters would indicate the use of aconfinement well of at least 45 μm (25 μm+(2*10 μm)) in its smallestdimension. Even for a 1 pL droplet, the droplet diameter is 12 μm, whichindicates a confinement well of at least 32 μm in its smallestdimension.

Various pixel layouts that rely on a confinement well of at least 45 μmin its smallest dimension can be used in OLED displays having aresolution up to 100 ppi. However, in high resolution displays ofgreater than 100 ppi, for example, 10 pL droplets are too large anddroplet placement accuracies too poor to reliably provide for consistentloading of droplets into confinement wells around each sub-pixel. Inaddition, as noted above, for high resolution displays, covering anincreased amount of display area with structures used to defineconfinement wells can negatively impact the fill factor of each pixel,where fill factor is defined as the ratio of the light emitting area ofthe pixel relative to the total pixel area. As fill factor decreases,each pixel must be driven harder to achieve the same overall displaybrightness thereby decreasing longevity and performance of each pixel ofthe display.

To further illustrate some of the above mentioned challenges of workingwith very high resolution displays, FIG. 1 illustrates one conventionalpixel layout 1700. Pixel 1750 can comprise sub-pixels 1720, 1730, 1740arranged in a side-by-side configuration, sub-pixel 1720 beingassociated with light emission in the red spectrum range, sub-pixel 1730being associated with light emission in the green spectrum range, andsub-pixel 1740 being associated with light emission in the blue spectrumrange. Each sub-pixel can be surrounded by confinement structures 1704forming confinement wells directly corresponding to the sub-pixels 1720,1730, 1740. One sub-pixel electrode can be associated with eachconfinement well such that electrode 1726 corresponds to sub-pixel 1720,electrode 1736 corresponds to sub-pixel 1730, and electrode 1746corresponds to sub-pixel 1740. Sub-pixel 1720 can have a width D,sub-pixel 1730 can have a width C, and sub-pixel 1740 can have a widthB, which may be the same or differ from each other. As shown, allsub-pixels can have a length A. In addition, dimensions E, F, and G canindicate the spacing between confinement well openings. Values assignedto dimensions E, F, G can be very large in some instances, e.g., greaterthan 100 μm, particularly in lower resolution displays. However, forhigher resolution displays, it is desirable to minimize these dimensionsin order to maximize the active pixel area and thus maximize the fillfactor. As illustrated in FIG. 1, the active pixel area, indicated bythe shaded regions, is the entire area within each of the sub-pixelconfinement wells.

Various factors can influence dimensions E, F, G, such as, for example,the minimum value for these dimensions can be restricted by theprocessing method. For example, in various illustrative embodimentsdescribed herein E=F=G=12 μm as a minimum dimension. For example, in adisplay having a 326 ppi resolution, the pixel pitch can be equal to 78μm and E=F=G=12 μm. The confinement wells associated with each of thesub-pixels 1720, 1730, 1740 can have a target droplet area of 14 μm×66μm (i.e. dimensions B×A, C×A, and D×A) where 14 μm is significantly lessthan the 45 μm smallest dimension discussed above regarding using inkjetdroplets having a volume of 10 pL. It is also less than the 32 μmdimension discussed above for 1 pL droplets. In addition, the fillfactor of the pixel, defined as the ratio of the active pixel area (i.e.the area associated with light emission), and the total pixel area is46%. In other words, 54% of the pixel area corresponds to confinementstructures 1704. Along the same lines, in a display having a 440 ppiresolution, the pixel pitch, P, can be equal to 58 μm and E=F=G=12 μm.Confinement wells associated with each of the emitting sub-pixels 1720,1730, 1740 can have a target droplet area of, for example, 7 μm×46 μmwhere a dimension of 7 μm is significantly less than the minimumdimensions discussed above for accurate droplet placement of both 10 pLand 1 pL inkjet droplets. In this instance, the fill factor for adisplay having 440 ppi is around 30%.

Deposition techniques in accordance with various exemplary embodimentsdescribed herein can provide improved reliability in loading ofconfinement wells and deposition of active OLED layers for electronicdisplays, such as, for example, high resolution displays. Active OLEDlayers can include, for example, one or more of the following layers: ahole injection layer, a hole transport layer, an electron blockinglayer, an organic light emissive layer, an electron transport layer, anelectron injecting layer, and a hole blocking layer. Implementation ofsome of the above-identified active OLED layers is preferred andimplementation of some active OLED layers is optional for electronicdisplays. For example, at least one hole conducting layer such as a holeinjection layer or a hole transport layer must be present as well as anorganic light emissive layer. All other above-identified layers may beincluded as desired to alter (e.g., improve) light emission and powerefficiency of an electronic display such as an OLED display.

Various exemplary embodiments of confinement well configurationsdescribed herein can increase the size of the confinement well whilemaintaining high pixel resolution. For instance, various exemplaryembodiments use relatively large confinement wells that span a pluralityof sub-pixels, thereby enabling the use of relatively attainable dropletsizes and conventional printing system accuracies in the deposition ofthe active OLED layers, while also achieving relatively high pixeldensities. Accordingly, inkjet nozzles that deposit droplet volumes inthe range from 1 pL to 50 pL can be used, rather than requiringspecially configured or reconfigured printheads with smaller dropletvolumes and new printing systems, which may or may not be available.Moreover, by using such larger confinement wells, small manufacturingerrors will not have a significant negative effect on depositionprecision and the deposited active OLED layers can remain containedwithin the confinement well.

In accordance with various exemplary embodiments, inkjet printingtechniques can provide sufficiently uniform deposition of active OLEDlayers. For example, various components typically used in OLED displaysresult in topographies of varying heights on the top surface layer of aconfinement well, for example, heights differing by about 100 nanometers(nm) or more. For instance, components such as electrodes may bedeposited on a substrate such that a gap is formed between neighboringelectrodes in order to form separately addressable electrodes eachassociated with a differing sub-pixel. Regardless of which active OLEDlayers are deposited over the electrodes disposed on the substrate ofthe display, height differentials between the plane of the top surfacesof the electrodes and the top surface of the substrate of the display inregions between neighboring electrodes can contribute to the topographyof the subsequently deposited OLED layers. Exemplary inkjet printingtechniques and resulting displays in accordance with the presentdisclosure allow the active OLED layers to be deposited such that thethickness of the active OLED layers are sufficiently uniform, forexample over the active electrode region, where active electrode regionscan be regions of the electrode associated with the active sub-pixelarea from which light is emitted. In an exemplary embodiment, athickness of the OLED layer, at least over the active electrode region,can be less than the thickness of the sub-pixel electrodes. Sufficientlyuniform thicknesses of the OLED layers over the active electrode areacan reduce undesirable visual artifacts. For example, OLED inkformulations and printing processes can be implemented to minimizenon-uniformity in the deposited film thickness within a given depositionarea, even when that area includes both electrode and non-electroderegions. In other words, portions within the deposition area not coveredby an electrode structure can contribute to the OLED layer topographysuch that the OLED layer can sufficiently conform to the underlyingstructures over which it is deposited within the deposition area.Minimizing non-uniformities in the deposited film thickness can providefor substantially uniform light emission when a particular sub-pixelelectrode is addressed and activated.

In accordance with yet other exemplary embodiments, pixel layoutconfigurations contemplated by the present disclosure can increaseactive region areas. For example, confinement structures can defineconfinement wells having a contiguous area that spans a plurality ofsub-pixels such that non-active portions (e.g., substrate areasassociated with confinement structures) of the display are reduced. Forinstance, rather than a confinement structure surrounding each sub-pixelelectrode as in various conventional OLED displays, a plurality ofindividually addressed sub-pixel electrodes can be surrounded by aconfinement structure where each sub-pixel electrode can be associatedwith a differing pixel. By reducing the area taken up by the confinementstructures, the fill factor can be maximized because the ratio of thenon-active region to the active region of each pixel is increased.Achieving such increases in fill factor can enable high resolution insmaller size displays, as well as improve the lifetime of the display.

In accordance with yet other exemplary embodiments, the presentdisclosure contemplates an organic light-emissive display that includesa confinement structure disposed on a substrate, wherein the confinementstructure defines a plurality of wells in an array configuration. Thedisplay further includes a plurality of electrodes disposed within eachwell and spaced apart from one another. The display further can includefirst, second, and third organic light emissive layers in at least oneof the plurality of wells, each layer having first, second, and thirdlight emissive wavelength ranges, respectively. A number of electrodesdisposed within the well associated with the first and second organiclight-emissive layer differs from a number of electrodes disposed withinthe well associated with the third organic light emissive layer.

In accordance with yet other exemplary embodiments, the presentdisclosure contemplates an organic light-emissive display that includesa confinement structure disposed on a substrate, wherein the confinementstructure defines a plurality of wells in an array configuration,including a first well, a second well, and a third well. The displayfurther can include a first plurality of electrodes disposed within thefirst well and associated with a differing pixel, a second plurality ofelectrodes disposed within the second well and associated with adiffering pixel, and at least one third electrode disposed within thethird well, wherein a number of electrodes disposed within each of thefirst and second wells differs from a number of electrodes disposedwithin the third well. The display can further include a first organiclight emissive layer having a first light-emissive wavelength rangedisposed in the first well, a second organic light emissive layer havinga second light-emissive wavelength range disposed in the second well,and third organic light emissive layer having a third light-emissivewavelength range disposed in the third well.

In accordance with various other exemplary embodiments, pixel layoutconfigurations can be arranged to extend the lifetime of the device. Forexample, sub-pixel electrode size can be based on the correspondingorganic light-emission layer wavelength range. For instance, a sub-pixelelectrode associated with light emission in the blue wavelength rangecan be larger than a sub-pixel electrode associated with light emissionin the red or green wavelength ranges, respectively. Organic layersassociated with blue light emission in OLED devices typically haveshortened lifetimes relative to organic layers associated with red orgreen light emission. In addition, operating OLED devices to achieve areduced brightness level increases the lifetime of the devices. Byincreasing the emission area of the blue sub-pixel relative to the redand green sub-pixels, respectively, in addition to driving the bluesub-pixel to achieve a relative brightness less than a brightness of thered and green sub-pixels (e.g., by adjusting the current supplied whenaddressing the sub-pixel as those of ordinary skill in the art arefamiliar with), the blue sub-pixel can serve to better balance thelifetimes of the differing colored sub-pixels while still providing forthe proper overall color balance of the display. This improved balancingof lifetimes can increase the overall lifetime of the display byextending the lifetime of the blue sub-pixels.

FIG. 2 illustrates a partial, plan view of one exemplary pixelarrangement of an organic light-emitting diode (OLED) display 100according to an exemplary embodiment of the present disclosure. FIG. 3Aillustrates a cross-sectional view along section 3A-3A identified inFIG. 2 of one exemplary embodiment of a substrate, depicting variousstructures for forming an OLED display. FIG. 3B illustrates across-sectional view along section 3B-3B identified in FIG. 2 of oneexemplary embodiment of a substrate, depicting various structures forforming an OLED display.

The OLED display 100 generally includes a plurality of pixels, e.g.,such as defined by dotted line boundaries 150, 151, 152, that whenselectively driven emit light that can create an image to be displayedto a user. In a full color display, a pixel 150, 151, 152 can include aplurality of sub-pixels of differing colors. For example, as illustratedin FIG. 2, pixel 150 can include a red sub-pixel R, a green sub-pixel G,and a blue sub-pixel B. As can be seen in the exemplary embodiment ofFIG. 2, sub-pixels need not be the same size, although in an exemplaryembodiment they could be. Pixels 150, 151, 152 can be defined by drivingcircuitry that cause light emission such that no additional structure isnecessary to define a pixel. Alternatively, exemplary embodiments of thepresent disclosure contemplate various new arrangements of pixeldefinition structures that can be included within display 100 todelineate the plurality of pixels 150, 151, 152. Those having ordinaryskill in the art are familiar with materials and arrangements ofconventional pixel definition structures used to provide crisperdelineation between pixels and sub-pixels.

With reference to FIGS. 3A and 3B in addition to FIG. 2, OLED display100 can include a substrate 102. Substrate 102 can be any rigid orflexible structure that can include one or more layers of one or morematerials. Substrate 102 can include, for example, glass, polymer,metal, ceramic, or combinations thereof. While not illustrated forsimplicity, substrate 102 can include additional electronic components,circuits, or conductive members, with which those having ordinary skillin the art have familiarity. For instance, thin-film transistors (TFTs)(not shown) can be formed on the substrate before depositing any of theother structures that are discussed in further detail below. TFTs caninclude, for example, at least one of a thin film of an activesemiconductor layer, a dielectric layer, and a metallic contact wherethose of ordinary skill in the art would be familiar with materials usedin the manufacture of such TFTs. Any of the active OLED layers can bedeposited to conform to any topography created by TFTs or otherstructures formed on substrate 102, as discussed below.

Confinement structures 104 can be disposed on the substrate 102 suchthat the confinement structures 104 define a plurality of confinementwells. For instance, the confinement structures 104 can be a bankstructure. A plurality of sub-pixels can be associated with eachconfinement well and the organic light-emissive material depositedwithin each confinement well allows all sub-pixels associated with theconfinement well to have the same light emission color. For example, inthe arrangement of FIG. 2, confinement well 120 can receive droplets ofOLED ink associated with sub-pixels that emit red light denoted by R,confinement well 130 can receive droplets of OLED ink associated withsub-pixels that emit green light denoted by G, and confinement well 140can receive droplets of OLED ink associated with sub-pixels that emitblue light denoted by B. Those having ordinary skill in the art wouldappreciate, as will be further explained below, that the confinementwells can also receive various other active OLED layers, including butnot limited to, for example, additional organic light-emissive materialand a hole conducting layer.

The confinement structures 104 can define confinement wells 120, 130,140 to confine material associated with a plurality of sub-pixels. Inaddition, confinement structures 104 can prevent spreading of OLED inkinto adjacent wells, and/or can assist (through appropriate geometry andsurface chemistry) in the loading and drying process such that thedeposited film is continuous within the region bounded by confinementstructures 104. For example, edges of the deposited films can contactthe confinement structures 104 that surround the confinement wells 120,130, 140. The confinement structures 104 can be a single structure orcan be composed of a plurality of separate structures that form theconfinement structures 104.

The confinement structures 104 can be formed of various materials suchas, for example, photoresist materials such as photoimageable polymersor photosensitive silicone dielectrics. The confinement structures 104can comprise one or more organic components that are, after processing,substantially inert to the corrosive action of OLED inks, have lowoutgassing, have a shallow (e.g. <25 degrees) sidewall slope at theconfinement well edge, and/or have high phobicity towards one or more ofthe OLED inks to be deposited into the confinement well, and may bechosen based on the desired application. Examples of suitable materialsinclude, but are not limited to PMMA (poly-methylmethacrylate), PMGI(poly-methylglutarimide), DNQ-Novolacs (combinations of the chemicaldiazonaphithoquinone with different phenol formaldehyde resins), SU-8resists (a line of widely used, proprietary epoxy based resistsmanufactured by MicroChem Corp.), fluorinated variations of conventionalphotoresists and/or any of the aforementioned materials listed herein,and organo-silicone resists, each of which can be further combined witheach other or with one or more additives to further tune the desiredcharacteristics of the confinement structures 104.

Confinement structures 104 can define confinement wells that have anyshape, configuration, or arrangement. For example, the confinement wells120, 130, 140 can have any shape such as rectangular, square, circular,hexagonal, etc. Confinement wells in a single display substrate can havethe same shape and/or size or differing shapes and/or sizes. Confinementwells associated with differing light emission colors can have differingor the same shapes and/or sizes. Moreover, adjacent confinement wellscan be associated with alternating light emission colors or adjacentconfinement wells can be associated with the same light emission colors.In addition, confinement wells can be arranged in columns and/or rowswhere the columns and/or rows can have uniform or non-uniform alignment.

The confinement wells can be formed using any of a variety ofmanufacturing methods, such as, for example, inkjet printing, nozzleprinting, slit coating, spin coating, spray coating, screen printing,vacuum thermal evaporation, sputtering (or other physical vapordeposition method), chemical vapor deposition, etc. and any additionalpatterning not otherwise achieved during the deposition technique can beachieved by using shadow masking, one or more photolithography steps(e.g. photoresist coating, exposure, development, and stripping), wetetching, dry etching, lift-off, etc.

As illustrated in FIG. 2, confinement wells 120, 130, 140 according tovarious exemplary embodiments, can be defined by the confinementstructures 104 such that they span a plurality of pixels 150, 151, 152.For example, pixel 150 includes a red sub-pixel R, a green sub-pixel G,and a blue sub-pixel B that are each part of a differing confinementwell 120, 130, 140. Each confinement well 120, 130, 140 can include aplurality of electrodes, such as 106, 107, 108, 109, 136, 137, 138, 139,142, 144, wherein the electrodes within the confinement wells 120, 130,140 can be spaced apart from each other such that a gap S is formedbetween adjacent electrodes within a confinement well. In exemplaryembodiments, the gap S can be of sufficient size to electrically isolatean electrode from any adjacent electrode, and in particular, the activeelectrode regions of adjacent electrodes can be isolated from oneanother. The gap or space S can reduce current leakage and improvesub-pixel definition and overall pixel definition.

While omitted for clarity and ease of illustration, drive circuitry canbe disposed on the substrate 102, and such circuitry can be disposedeither beneath the active pixel areas (i.e., the light emitting regions)or within the non-active pixel areas (i.e., the non-light emittingregions). In addition, while not illustrated, circuitry can also bedisposed under confinement structures 104. The drive circuitry can becoupled to each electrode such that each electrode can be selectivelyaddressed independently of the other electrodes within the confinementwell. The region of non-uniform topography that results due to the gap Sbetween electrodes is described in further detail below.

Each electrode 106, 107, 108, 109, 136, 137, 138, 139, 142, 144 within aconfinement well 120, 130, 140 can be associated with a differingsub-pixel. For example, as illustrated in FIG. 2, confinement well 120can be associated with red light emission. Electrodes 106, 107, 108, 109can be positioned within the confinement well 120 where each electrodeis operable to address a sub-pixel of a differing pixel (e.g., pixels151 and 152 being illustrated). At least two electrodes can bepositioned within each confinement well 120, 130, 140. The number ofelectrodes positioned within each confinement well 120, 130, 140 can bethe same or differing from other confinement wells. For example, asillustrated in FIG. 2, confinement well 140 can include two sub-pixelelectrodes 142, 144 associated with blue light emission and confinementwell 130 can include four sub-pixel electrodes 136, 137, 138, 139associated with green light emission.

In an exemplary embodiment, the confinement structures 104 can bedisposed on a portion of the electrodes 106, 107, 108, 109, 136, 137,138, 139, 142, 144. As illustrated in FIGS. 3A and 3B, the confinementwell 120 can be defined by the confinement structures 104 where theconfinement structures 104 are disposed partially over a portion ofelectrodes 106, 108 and partially directly over substrate 102 withoutbeing over an electrode. Alternatively, the confinement structures 104can be disposed over the substrate 102 between electrodes of adjacentconfinement wells. For example, the confinement structures 104 can bedisposed on substrate 102 in a space formed between electrodesassociated with a differing sub-pixel emission color such that theconfinement structures 104 are directly disposed on substrate 102 andare not disposed over any portion of an electrode. In such aconfiguration (not illustrated), the electrodes corresponding tosub-pixels can be disposed either directly adjacent to (in abutmentwith) the confinement structures 104 or the electrodes can be spacedapart from the confinement structures 104 such that sub-pixel definitioncan be achieved.

When a voltage is selectively applied to an electrode 106, 107, 108,109, 136, 137, 138, 139, 142, 144, light emission can be generatedwithin a sub-pixel of a pixel, such as, pixels 150, 151, 152. Electrodes106, 107, 108, 109, 136, 137, 138, 139, 142, 144, can be transparent orreflective and can be formed of a conductive material such as a metal, amixed metal, an alloy, a metal oxide, a mixed oxide, or a combinationthereof. For example, in various exemplary embodiments, the electrodesmay be made of indium-tin-oxide, magnesium silver, or aluminum.Electrodes 106, 107, 108, 109, 136, 137, 138, 139, 142, 144, can haveany shape, arrangement, or configuration. For example, referring to FIG.3A, electrodes 106, 107, 108, 109, 136, 137, 138, 139, 142, 144, canhave a profile such that the top surface 106 a, 108 a can besubstantially planar and parallel to the surface of the substrate 102while the side edges 106 b, 108 b of the electrodes can be substantiallyperpendicular to or can be angled and/or rounded with respect to thesurface of the substrate.

It is further noted that the active portion of the electrode, i.e. theportion associated with light emission, are those portions of theelectrode which are disposed directly underneath the deposited OLEDlayers without any intervening insulating substrate structures betweenthe electrode surface and the OLED layers. By way of example, again withreference to FIG. 3A, the portions of electrodes 106 and 108 that aredisposed beneath confinement structures 104 are excluded from the activeportion of the electrode area, whereas the remainder of the regions ofelectrodes 106 and 108 are included in the active portion of theelectrode area.

The electrodes may be deposited in various ways, such as, by a thermalevaporation, chemical vapor deposition, or sputtering method. Thepatterning of the electrodes may be achieved, for example, using shadowmasking or photolithography. As mentioned above, electrodes 106, 107,108, 109, 136, 137, 138, 139, 142, 144 can have a thickness and bespaced apart such that a topography is formed on the substrate 102,shown best in the various cross-sectional views, such as in FIG. 3A. Inan exemplary embodiment, electrodes 106, 107, 108, 109, 136, 137, 138,139, 142, 144 can have a thickness ranging from 60 nm to 120 nm, thoughthis range is nonlimiting and larger or smaller thicknesses are possibleas well.

One or more active OLED layers can be provided within each confinementwell 120, 130, 140 such as hole conducting layer 110 and organic lightemissive layer 112 shown in FIGS. 3A and 3B. The active OLED layers canbe deposited such that they can sufficiently conform to the topographiesthat result from thickness of and spacing between the electrodes 106,107, 108, 109, 136, 137, 138, 139, 142, 144 within a confinement well120, 130, 140, as well as the thickness of the respective active OLEDlayers. For example, the active OLED layers can be continuous within awell and have a thickness so as to sufficiently conform and follow theresultant topography of the underlying electrode structures disposedwithin each confinement well.

The deposited OLED layers may therefore result in a surface topographythat does not lie in a single plane parallel to the substrate and acrossthe entire confinement well. For example, one or both of OLED layers110, 112 can be non-planar and discontinuous in a single plane of thedisplay (wherein the plane of the display is intended as a planeparallel to substrate 102) due to the relative depression or protrusionassociated with any surface feature including electrodes disposed onsubstrate 102. As shown, the OLED layers 110, 112 can sufficientlyconform to underlying surface feature topographies such that a topsurface of the OLED layer can have a resulting topography that followsthe topography of the underlying surface features. In other words, eachdeposited OLED layer sufficiently conforms to all underlying layersand/or surface features disposed on the substrate 102 such that thoseunderlying layers contribute to the resulting non-planar top surfacetopography of the OLED layers after they are deposited. In this way, ina plane across the confinement well that is parallel to a plane of thedisplay, a discontinuity in layer 110 or 112, or both, can arise as thelayer(s) rise and/or fall, relative to the plane, with the existingsurface features provided from electrodes, circuitry, pixel definitionlayers, etc., in the confinement well. While the active OLED layers 110and/or 112 need not perfectly conform to the underlying surfacetopography (for example, as explained below there may be localnon-uniformities in thickness around edge regions and the like), asufficiently conformal coating in which there are no significantbuild-ups or depletions of material can promote a more even, uniform,and repeatable coating.

As shown in FIG. 3A, each layer 110, 112 can be substantially continuouswithin the entire confinement well 120 such that each layer is disposedover substantially all surface features within the confinement well 120(e.g. sub-pixel electrodes, circuitry, pixel definition layers, etc.)where the edges of each layer contact the confinement structures 104surrounding the confinement well 120. In various exemplary embodiments,active OLED layer material can be deposited to form a discretecontinuous layer entirely within a confinement well to substantiallyprevent any discontinuities in the layer within the well (in other wordsa region within the well where the active OLED layer material ismissing). Such discontinuities can cause undesirable visual artifactswithin the emission region of a sub-pixel. It is worth noting thatthough each layer 110, 112 is substantially continuous within theconfinement well, it can nonetheless be discontinuous in a single plane,as noted above, due to the rising/falling of the layer as itsufficiently conforms to existing topographies of features disposed inthe confinement well over which the layers are deposited. For example,in exemplary embodiments, if such a rise and/or fall is by an amount,e.g., 100 nm, greater than the thickness of the thinnest part of thedeposited layer within the well, e.g., 50 nm, the OLED material layerwill not be continuous in a plane parallel to the display within thewell.

The layers 110, 112 can have a substantially uniform thickness withineach confinement well which may provide for more uniform light emission.For the purpose of this application, substantially uniform thickness canrefer to an average thickness of the OLED layer over planar surfaceregions, such as over active electrode regions, but also can encompassminute variations or local non-uniformities in thickness as describedbelow. Over the planar surface regions, e.g. 106 a, 108 a, and bottomsurface of gaps in FIG. 3A, it is anticipated that for a substantiallyuniform OLED coating the variation in thickness from an averagethickness of the OLED layer can be less than ±20%, such as less than±10% or less than ±5%.

As noted above, however it is contemplated that local non-uniformitiesin thickness may arise in portions of the layers 110, 112 surroundingchanges in surface topography and/or surface chemistry, and in suchregions, the film thickness can locally deviate substantially from the±20%, ±10%, or ±5% parameters specified above. For example, localnon-uniformities in the thickness of a continuous layer can occur due tothe topography associated with surface features disposed on substrate102 and/or a change in surface chemistry between the surface featuresdisposed on the substrate 102 such as at the edge of the confinementwell structures 104, at the edge of a pixel definition layer (discussedbelow), on the electrode edge sidewalls (e.g. along 106 b, 108 b), orwhere the electrode meets the substrate surface. Local non-uniformitiescan lead to deviations in film thickness. For example, the localnon-uniformities can deviate from the thickness of the layers 110, 112provided over the active electrode regions (e.g. along 106 a, 108 a) ofelectrodes 106, 108. The non-uniformities can create generally localized“edge effect” deviations within a range of approximately 5 μm-10 μmaround such surface features disposed on substrate 102 in theconfinement well, such as at edges of electrodes, circuitry, pixeldefinition layers, etc. For the purposes of this application, such “edgeeffect” deviations are intended to be encompassed when describing theOLED film coating as having a “substantially uniform thickness” withinthe well.

In an exemplary embodiment, the thickness of each layer 110, 112 can beequal to or less than the thickness of the electrodes such that theupper surface of each layer does not lie in a single plane parallel tothe plane of the display (i.e., a plane parallel to the substrate) dueto the dip in the film formed as the layer traverses the gap between theactive regions of the electrodes. This is illustrated, for example, inFIG. 3A, wherein a dashed line is provided to illustrate a plane P thatis parallel to the plane of the substrate 102. As shown, layers 110, 112can each have an average thickness that is substantially uniform withinthe region of layers 110, 112 over with the active electrode regions ofelectrodes 106, 108. However, layers 110, 112 can also include small andlocalized non-uniform thickness in areas associated with topographychanges caused by the surface features such as around edges of thosesurface features (e.g. edges of electrodes 106, 108 adjacent to thegap).

The layers 110, 112 can be deposited using any manufacturing method. Inan exemplary embodiment, the hole conducting layer 110 and the organiclight-emission layer 112 can be deposited using inkjet printingtechniques. For example, the material of hole conducting layer 110 canbe mixed with a carrier fluid to form an inkjet ink that is formulatedto provide reliable and uniform loading into the confinement wells. Theink for depositing hole conducting layer 110 can be delivered to thesubstrate at high speeds from an inkjet head nozzle into eachconfinement well. In various exemplary embodiments, the same holeconducting material can be delivered to all of the confinement wells120, 130, 140 so as to provide for depositing of the same holeconducting layer 110 within all of the confinement wells 120, 130, 140.After material is loaded into the confinement wells to form holeconducting layer 110, the display 100 can be dried to allow any carrierfluid to evaporate, a process which can include exposing the display toheat, to vacuum, or ambient condition for a set period of time.Following drying, the display may be baked at an elevated temperature soas to treat the deposited film material, for example, to induce achemical reaction or change in film morphology that is beneficial forthe quality of the deposited film or for the overall process. Thematerial associated with each organic light-emissive layer 112 can besimilarly mixed with a carrier fluid such as an organic solvent or amixture of solvents to form inkjet inks that are formulated to providereliable and uniform loading into the confinement wells. These inks canthen be inkjet deposited using an inkjet process within the appropriateconfinement wells 120, 130, 140 associated with each emission color. Forexample, the ink associated with the red organic light-emissive layer,the ink associated with the green organic light-emissive layer, and theink associated with the blue organic light-emissive layer are separatelydeposited into the corresponding confinement wells 120, 130, 140. Thediffering organic light-emissive layers 112 can be depositedsimultaneously or sequentially. After loading with one or more of theinks associated with the organic light emissive layers, the display canbe similarly dried and baked as described above for the hole conductinglayer.

While not illustrated, additional active OLED layers of material can bedisposed within the confinement well. For example, OLED display 100 canfurther include a hole injection layer, a hole transport layer, anelectron blocking layer, a hole blocking layer, an electron transportlayer, an electron injection layer, a moisture protection layer, anencapsulation layer, etc., all of which those having ordinary skill inthe art are familiar with but are not discussed in detail here.

The hole conducting layer 110 can include one or more layers of materialthat facilitates injection of holes into the organic light-emissivelayer 112. For example, hole conducting layer 110 can include a singlelayer of hole conducting material such as, for example, a hole injectionlayer. Alternatively, hole conducting layer 110 can include a pluralityof layers such as at least one of a hole injection layer, such asPoly(3,4-ethylenedioxythiophene:poly(styrenesulfonate) (PEDOT:PSS), anda hole transport layer, such asN,N′-Di-((1-napthyl)-N,N′-diphenyl)-1,1′-biphenyl)-4,4′-diamine (NPB).

The organic light-emissive layer 112 can be deposited over the holeconducting layer 110 such that organic light-emissive layer 112sufficiently conforms to the topography created by the electrodes, thespace between the electrodes, and the topography of the hole conductinglayer. The organic light-emissive layer 112 can include material tofacilitate light emission such as an organic electroluminescencematerial.

In an exemplary embodiment, the thickness of the OLED stack (e.g. allactive OLED layers deposited over the electrodes within a confinementwell) can range from 10 nm to 250 nm. For example, a hole transportlayer can having a thickness ranging from 10 nm to 40 nm; a holeinjection layer can have a thickness ranging from 60 nm to 150 nm; anorganic light-emissive layer can have a thickness ranging from 30 nm-150nm, and optionally a hole blocking layer, electron transport layer, andelectron injection layer having combined thickness ranging from 10 nm to60 nm.

In an exemplary embodiment, it is contemplated that droplets having avolume of about 10 pL or less may be used to produce each of layers 110,112. In various exemplary embodiments, droplet volumes of 5 pL or less,3 pL or less, or 2 pL or less may be used. The OLED layers 110, 112 canbe formed using from 1 to 20 droplets having the above describedvolumes.

In one exemplary and nonlimiting embodiment, the present disclosurecontemplates confinement wells arranged such that the areas of the wellsassociated with red, green, or blue light emissions 120, 130, 140 can be66 μm×66 μm for displays having a resolution of 326 ppi (e.g., Pitch=78um) where the width between neighboring wells in this embodiment can be12 μm. The area associated with red or green sub-pixel light emission ofsuch an arrangement can be 31.5 μm×31.5 μm, and the area associated withblue sub-pixel light emission can be 66 μm×30 μm, leading to an overallpixel fill factor of 65%, as compared to the fill factor of 46% for theconventional RGB side-by-side layout described with reference to FIG. 1.For another exemplary and nonlimiting embodiment, a display having aresolution of 440 ppi (e.g., Pitch=58 μm), it is contemplated to arrangeconfinement wells such that areas of the wells associated with red,green, or blue light emissions 120, 130, 140 can be 46 μm×46 μm, whereagain the width between neighboring wells in this embodiment is 12 μm.An area associated with red or green sub-pixel light emission of such adisplay structure can be 20.3 μm×20.3 μm, while an area associated withblue sub-pixel light emission can be 76 μm×49.1 μm, thereby producing afill factor of approximately 46%, as compared to the fill factor of 30%for the conventional RGB side-by-side layout described with reference toFIG. 1. In these embodiments the width between adjacent wells can be 12μm, but as discussed above, this width can take on different values, andwhile a smaller value may be desirable (to provide for a greaterproportion of the substrate area assigned to the active electrodeareas), processing constraints on the formation of the well structureand circuit layout constraints may effectively set a lower bound on thisdimension. The value of 12 μm is selected as representative for theseexamples, but one having ordinary skill in the art would appreciate thatother dimensions could be used, for example, larger dimensions like 20μm, or smaller dimensions, like 8 μm, 6 μm, or even 1 μm withoutdeparting from the scope of the present disclosure and claims. Onehaving ordinary skill in the art can further appreciate that while inthe above examples, the red, green, and blue confinement wells each haveidentical dimensions, other arrangements are possible. For example, twoconfinement wells associated with differing emission colors can have thesame dimensions and one confinement well associated with yet anotherdiffering emission color can have a differing dimension or theconfinement wells associated with each emission color can have differingdimensions.

These exemplary, non-limiting arrangements in accordance with thepresent disclosure provide for confinement wells having minimum welldimensions of greater than 45 μm even for the very high resolution caseof 440 ppi, and therefore can permit droplet volumes, for example, ofaround 10 pL, to be used, thereby simplifying manufacturing by allowingfor the use of droplet volumes that are available from existing inkjetprinting. In addition, the above exemplary, non-limiting arrangementsincrease pixel fill factor as compared to a conventional RGBside-by-side layout by about 43% and 84% for the 326 ppi and 440 ppicases respectively. More generally, the various exemplary embodiments inaccordance with the present disclosure provide enhancements in the fillfactor of high resolution displays manufactured using inkjet, such asvery high resolution displays, for which enhancements of 40% or more arepossible.

As those of ordinary skill in the art are familiar with, a commonelectrode (not shown) can be disposed over the organic light-emissivelayer 112 following deposition. After the common electrode is deposited,the resulting topography of the common electrode can sufficientlyconform to topography of organic light-emissive layer 112. The commonelectrode can be deposited using any manufacturing technique, forexample, by vacuum thermal evaporation, sputtering, chemical vapordeposition, spray coating, inkjet printing, or other techniques. Thecommon electrode can be transparent or reflective and can be formed of aconductive material such as a metal, a mixed metal, an alloy, a metaloxide, a mixed oxide, or a combination thereof. For example, indium tinoxide or a thin layer of magnesium silver. The thickness of the commonelectrode can range from approximately 30 nm to 500 nm.

In addition, the common electrode can have any shape, arrangement, orconfiguration. For example, the common electrode can be disposed as adiscrete layer associated with single sub-pixel, or a single pixel.Alternatively, the common electrode can be disposed over multiplesub-pixels or pixels, for example, over the entire pixel arrangement ofthe display 100. For instance, the common electrode can be blanketdeposited within the confinement wells 120, 130, 140 as well as over theconfinement structures 104. Additional active OLED layers (not shown forsimplicity) can be deposited onto the organic light emissive layer 112before deposition of a common electrode, such as electron transportlayers, electronic injection layers, and/or hole blocking layers. Suchadditional OLED layers can be deposited by inkjet printing, by vacuumthermal evaporation, or by another method.

In accordance with exemplary embodiments, the OLED device 100 can have atop emissive configuration or a bottom emissive configuration. Forexample, as illustrated in FIG. 3A, in a top emissive configuration,electrodes 106, 108 can be reflective electrodes and the commonelectrode that is disposed over the organic light-emissive layer can bea transparent electrode. Alternatively, in a bottom emissiveconfiguration, electrodes 106, 108 can be transparent and the commonelectrode can be reflective.

In another exemplary embodiment, the OLED display 100 can be anactive-matrix OLED (AMOLED). An AMOLED display, as compared to apassive-matrix OLED (PMOLED) display, can enhance display performance,but relies on active drive circuitry, including thin film transistors(TFTs), on the substrate and such circuitry is not transparent. WhilePMOLED displays have some elements, such as conductive bus lines thatare not transparent, AMOLED displays have substantially more elementsthat are non-transparent. As a result, for a bottom emission AMOLEDdisplay, the fill factor may be reduced compared to a PMOLED becauselight can only be emitted through the bottom of the substrate betweenthe non-transparent circuit elements. For this reason, it may bedesirable to use a top emission configuration for AMOLED displays sinceusing such a configuration may permit the OLED device to be constructedon top of such non-transparent active circuit elements. Thus, light canbe emitted through the top of the OLED device without concern for theopacity of the underlying elements. In general, using a top emissionstructure can increase the fill factor of each pixel 150 of display 100because light emission is not blocked by additional non-transparentelements (e.g. TFTs, driving circuitry components, etc.) deposited onthe substrate 102.

In addition, non-active areas of each pixel can be limited to theconfinement structures, surface features, and/or pixel definition layers(examples of which are described in further detail below) formed on thesubstrate 102. A conductive grid also can be disposed on substrate 102to prevent an undesirable voltage drop across the display 100, which canarise because the transparent top electrodes used in top emission OLEDstructures typically have low conductivities. When the common electrodeis blanket deposited within the confinement wells 120, 130, 140 and overthe confinement structures 104, the conductive grid can be disposed onnon-active portions of the substrate 102 and coupled to the commonelectrode through via holes formed in selected confinement structures104. However, the present disclosure is not limited to a top emissionactive-matrix OLED configuration. The techniques and arrangementsdiscussed herein can be used with any other type of displays such asbottom emission and/or passive displays as well as those one of ordinaryskill in the art would understand how to make using appropriatemodifications.

In an exemplary embodiment, as illustrated in FIG. 3A, each confinementwell can include a plurality of active sub-pixel regions that span W1and W2, respectively, and are separated by gap S, and are confinedwithin a well having width CW. The dimensions, W1, W2, and CW areprimarily related to pixel pitch, which correlates to the resolution(e.g. 326 ppi, 440 ppi) of the display. The dimension of the gap S isrelated to restrictions associated with fabrication techniques andprocesses, and layout. In general, it may be desirable to minimize thedimension associated with the gap S. For example, 3 μm may be a minimumdimension; however, one of ordinary skill in the art would appreciatethat dimensions from as small as 1 μm to greater than 10 μm arepossible. The height H of confinement structures 104 is also related toprocessing restrictions rather than a particular display layout orresolution. While an exemplary value of the height H of confinementstructures 104 may be 1.5 μm, the height H, can range from 0.5 μm to 5μm in various exemplary embodiments. Referring to FIG. 3B, BW is thewidth of the confinement structures 104 between adjacent wells (e.g.,wells 120 and 130 in FIG. 3B). As described above, it may be desirableto minimize this dimension and an exemplary value is 12 μm. However, oneof ordinary skill would understand that this value can be arbitrarilylarge (e.g. hundreds of microns) in some instances, and can also be assmall as 1 μm, depending on fabrication techniques and processes thatmay permit such a small value for BW.

Referring now to FIG. 4, a cross-sectional view of an exemplaryembodiment of a confinement well 220 of a display 200 is illustrated.The arrangement of FIG. 4 is similar to that described above withreference to FIG. 3A, with like numbers used to represent like elementsexcept using the 200 series as opposed to the 100 series. Asillustrated, however, the OLED display 200 also includes an additionalsurface feature 216 disposed in the gap S between electrodes 206, 208.

Surface feature 216 can be any structure that does not directly provideelectrical current into the OLED films disposed over it, therebycomprising a non-active region of the pixel area between the activeregions associated with the electrodes 206 and 208. For example, thesurface feature 216 can further comprise an opaque material. As depictedin FIG. 4, a hole conducting layer 210 and organic light-emissive layer212 can be deposited over a portion of such circuitry elements, asrepresented topographically by surface feature 216. In the case thatsurface feature 216 contains electrical elements, such elements may befurther coated with an electrically insulating material so as toelectrically isolate those elements from the OLED films deposited ontosurface feature 216.

In an exemplary embodiment, surface feature 216 can include drivingcircuitry, including but not limited to, for example, an interconnect,bus lines, transistors, and other circuitry with which those havingordinary skill in the art are familiar. In some displays, drivingcircuitry is disposed proximal to the active region of the pixel drivenby such circuitry to minimize complicated interconnections and to reducethe voltage drop. In some cases, the confinement well would surround anindividual sub-pixel, and such circuitry can be outside the confinementwell region such that the circuitry would not be coated with active OLEDlayers. However, in the exemplary embodiment of FIG. 4, as well asothers described herein, because the confinement well 220 can contain aplurality of sub-pixels that are associated with differing pixels, suchdriving circuitry elements can be provided within the confinement wells,which may optimize the electrical performance of the drive electronics,optimize drive electronics layout, and/or optimize the fill factor.

The hole conducting layer 210 and organic light emissive layer 212 canbe deposited (as previously discussed, for example, with reference toFIGS. 3A and 3B) into the region defined by confinement well structures204 and over the surface feature 216 such that layers 210, 212sufficiently conform to underlying surface feature topographies and havea substantially uniform thickness in the confinement well, leading tolayers 210 and 212 having non-planar top surfaces. In the configurationwherein surface feature 216 extends above the plane of the top surfaceof the electrode a distance greater than the thickness of one or both ofthe layers 210 and 212, then one or both of those layers will also bediscontinuous in a plane parallel to the plane of the display within thewell 220. Thus, one or both layers 210, 212 will be non-planar anddiscontinuous in a plane parallel to the plane of the display due to theprotrusion associated with the surface feature 216. As above, this isillustrated, for example, by the dashed line illustrating a plane P thatis coplanar with the surface of 212 that is disposed over the electrodes206, 208. As shown, the layer 212 is not planar across the entireconfinement well and instead sufficiently conforms to the underlyingtopographies such that the layer 212 has an overall non-planar topsurface due to the gap region S and protrusion 216. In other words, oneor both of the layers 210, 212 will rise and fall across the confinementwell to sufficiently conform to the existing topography of the wellprior to the deposition of the layers 210, 212.

While the surface feature 216 is illustrated in FIG. 4 as having athickness greater than the electrodes, the surface feature 216 canalternatively have a thickness less than or equal to the electrodes.Moreover, while surface feature 216 is illustrated in FIG. 4 as beingdisposed on substrate 202, surface feature 216 can be further disposedover one or both of electrodes 206, 208. Surface feature 216 can differfor each confinement well in the array and not all confinement wellshave to include a surface feature. Surface feature 216 can furtherfunction as a pixel definition layer where the non-transparentproperties of surface feature 216 can be used to define portions ofsub-pixels or overall pixel arrangements.

Referring now to FIGS. 5A and 5B, partial cross-sectional views ofanother exemplary embodiment of a display confinement well in accordancewith the present disclosure is illustrated. The arrangement of FIGS. 5Aand 5B is similar to that described above with reference to FIGS. 3A and3B, with like numbers used to represent like elements except using the300 series as opposed to the 100 series. As illustrated in FIGS. 5A and5B, however, the OLED display 300 also includes a definition layer 314.Definition layer 314 can be deposited on substrate 302 where confinementstructures 304 can be disposed over the definition layer 314. Inaddition, definition layer 314 can be disposed over a non-active portionof electrodes 306, 308. Definition layer 314 can be any physicalstructure having electrically insulating properties used to defineportions of OLED display 300. In an embodiment, definition layer 314 canbe a pixel definition layer that can be any physical structure used todelineate pixels within the pixel array. Definition layer 314 can alsodelineate sub-pixels.

As illustrated, in an exemplary embodiment, the definition layer 314 canextend beyond the confinement structures 304 to over a portion ofelectrodes 306, 308. Definition layer 314 can be made of an electricallyresistant material such that the definition layer 314 prevents currentflow and thus can reduce unwanted visual artifacts by substantiallypreventing light emission through the edges of the sub-pixel. Definitionlayer 314 can also be provided to have a structure and chemistry tomitigate or prevent the formation of non-uniformities where the OLEDfilms coat over the edge of the definition layer. In this way,definition layer 314 can assist in masking film non-uniformities formedaround surface features that would otherwise be included in the activeregions of the pixel area and then contribute to pixel non-uniformity;such non-uniformities could occur, for example, at the exterior edges ofeach sub-pixel where the OLED films contact the confinement well, or atthe interior edges of the each sub-pixel where the OLED films contactthe substrate surface.

The hole conducting layer 310 and the organic light-emissive layer 312can each be deposited within the region defined by the confinementstructure 304 and over the pixel definition layers so as to form acontinuous layer within the confinement well 320. As described abovewith respect to FIGS. 3A and 3B, the layers 310, 312 can sufficientlyconform to the overall topography of the confinement well, and thus mayhave non-planar surfaces and/or be discontinuous in a plane of thedisplay, as illustrated for example by plane P in FIG. 5A. As explainedabove with reference to exemplary embodiment of FIG. 3A, the thicknessof the hole conducting layer 310 and the organic light-emissive layer312 can be substantially uniform, as described above.

In an exemplary embodiment, as illustrated in FIG. 5A, each confinementwell can include a plurality of active sub-pixel regions including W1and W2 separated by gap S and contained within a confinement well havingwidth CW, with W1, W2, and CW being primarily related to the pixelpitch, as discussed above with reference to FIG. 3A. Similarly, thedimension of the gap S is related to fabrication and processingtechniques, and layout, wherein S may range in exemplary embodimentsfrom 1 μm to greater than 10 μm, with, 3 μm being an exemplary dimensionfor S. The height H of confinement structures 304 may be as describedabove with reference to FIG. 3A. Referring to FIG. 5B, BW is, asdescribed above, the width of the confinement structures 304 betweenadjacent wells and can be selected as described above with reference toFIG. 3B.

The dimension T associated with the thickness of the definition layercan be variable based on fabrication techniques and processingconditions, and the type of definition layer material that is used. Invarious exemplary embodiments, the dimension T associated with thethickness of the definition layer can range from 25 nm to 2.5 μm, butfrom 100 nm to 500 nm can be considered the most typical range. Thedimensions labeled B1, B2 in FIG. 5A and B1, B1′ in FIG. 5B, associatedwith the extension of the definition layer beyond the edge of theconfinement structure 104 within the confinement wells, can be selectedas desired. However, a larger dimension may contribute to a reduction infill factor by reducing the amount of available active pixel electrodearea. Therefore, it may be desirable to select the minimum dimensionthat will serve the desired function, which is generally to exclude edgenon-uniformities from the active electrode area. In various exemplaryembodiments, this dimension can range from 1 μm to 20 μm, and may, forexample, range from 2 μm to 5 μm.

With reference now to FIG. 6, a cross-sectional view of an exemplaryembodiment of a confinement well 420 of a display 400 is illustrated.The arrangement of FIG. 6 is similar to that described above withreference to FIGS. 5A and 5B, with like numbers used to represent likeelements except using the 400 series as opposed to the 300 series. Asshown, however, the OLED display 400 also includes an additionaldefinition layer 416 disposed in the gap S between electrodes 406, 408.As shown in FIG. 6, the definition layer 416 can be a surface featurethat has a somewhat differing structure than the surface feature of FIG.4 in that a portion of the additional definition layer 416 extendsthroughout the gap S on the substrate 402 and over portions ofelectrodes 406, 408 adjacent the gaps. The additional definition layer416 can have any topography, with the one illustrated in FIG. 6 beingexemplary only. As illustrated in FIG. 6, a notch 417 can be present inthe surface of the additional definition layer 416 that faces away fromthe substrate 102. The notch 417 can be formed using various methods.For example, notch 417 may result from the manufacturing process suchthat during deposition of the additional definition layer 416, the layer416 can generally conform to any topography present within theconfinement well such as electrodes 406, 408 where notch 417 is formedby the differing thickness between a substantially uniform thicknessover the electrodes 406, 408 and a substantially non-uniform thicknesswith surfaces not associated the top surface of electrodes 406, 407.Alternatively, notch 417 can be omitted and the top surface ofadditional definition layer 416 can have a substantially planartopography, for instance, in the case that the additional definitionlayer 416 is deposited using a non-conformal deposition method such thatthe underlying surface topography is smoothed out.

In either configuration, the hole conducting layer 410 and/or theorganic light-emissive layer 412 can be deposited (as previouslydiscussed, for example, with reference to FIGS. 3A and 3B) such thatlayers 410, 412 sufficiently conform to the topography of the additionaldefinition layer 416 and have a substantially uniform thickness, as hasbeen described above.

The distance between the top surface (i.e., the surface facing away fromthe substrate) of the additional definition layer 416 and the substrate402 can be greater than or less than the distance between the topsurface of the electrodes 406, 408 and the substrate 402. Alternatively,the distance between the top surface of the additional definition layer416 and the substrate 402 can be substantially equal to the distancebetween the top surface of the electrodes 406, 408 and the substrate402. In other words, the thickness of the additional definition layer416 can be such that it ranges from being positioned between the topsurface of the substrate and the top surfaces of the surroundingconfinement structures 404, or such that it substantially lies in thesame plane as the top surfaces of the confinement structures 404.Alternatively, the additional definition layer 416 can be substantiallythe same height as the electrodes 406, 408 such that the additionaldefinition layer 416 does not overlap a portion of the electrodes 406,408, but rather fills in the gap S between them.

Hole conducting layer 410 and organic light-emissive layer 412 can bedisposed over the portions of definition layer 414 that extend beyondthe confinement structure 404 and into the well 420, and the layers 410,412 can extend over the additional definition layer 416 within theconfinement well 420 defined by confinement structure 404. Theadditional definition layer 416 can be made of an electrically resistantmaterial such that the additional definition layer 416 can preventcurrent flow and thus may reduce undesirable visual artifacts bypreventing light emission through the edges of the sub-pixel. Thedefinition layer 414 and the additional definition layer 416 can be madeof the same or differing materials.

In an exemplary embodiment, as illustrated in FIG. 6, each confinementwell can include a plurality of active sub-pixel regions including W1and W2 separated by gap S and contained within a confinement well havingwidth CW, with W1, W2, CW, and S being primarily related to the pixelpitch, as discussed above. As above, 3 μm may be a minimum dimension forS, but one of ordinary skill in the art would appreciate that dimensionsfrom as small as 1 μm to even greater than 10 μm are possible. Theheight H of confinement structures 404 can be chosen and with the rangesas described above with reference to FIGS. 3A and 3B, for example.

The dimension T1 associated with the thickness of the definition layerand the dimension T2 associated with the thickness of the additionaldefinition layer can be variable based on fabrication techniques,processing conditions and the type of definition layer material that isused. As a result, the dimension T1 associated with the thickness of thedefinition layer and the dimension T2 associated with the thickness ofthe additional definition layer can range from 50 nm to 2.5 μm, forexample, from 100 nm to 500 nm. The dimensions SB1, SB2, and B2associated with the extension of the definition layer inside the edge ofthe confinement well can be selected as desired. However, a largerdimension will contribute to a reduction in fill factor by reducing theamount of available active pixel electrode area. Therefore, it may bedesirable to select the minimum dimension that will serve the desiredfunction, which is generally to exclude edge non-uniformities from theactive electrode area. In various exemplary embodiments, this dimensioncan range from 1 μm to 20 μm, and may for example range from 2 μm to 5μm.

As those having ordinary skill in the art would appreciate based on thepresent disclosure, any of the disclosed definition layer configurationscan be used in any combination of differing ways to achieve a desirablepixel definition configuration. For example, definition layer 414 and/oradditional definition layer 416 can be configured to define any pixeland/or a sub-pixel region or any partial pixel and/or sub-pixel regionwhere definition layer 414 can be associated a definition layerdeposited under any confinement structures 404 and additional definitionlayer 416 can be associated with any definition layer deposited within aconfinement well between electrodes such as in confinement well 420. Anartisan of ordinary skill would recognize that the cross-sections shownwithin the present disclosure are merely illustrative cross-sections andtherefore the present disclosure is not to be limited to the specificcross-sections illustrated. For instance, while FIGS. 3A and 3B areillustrated along line 3A-3A and 3B-3B respectively, a differentcross-sectional view, taken along a different line, for exampleincluding in directions orthogonal to 3A-3A and 3B-3B, may reflectdiffering definition layer configurations. In an exemplary embodiment,definition layers can be used in combination to outline a pixel, such aspixels 150, 151, 152 illustrated in FIG. 2. Alternatively, definitionlayers can be configured to define a sub-pixel such that the definitionlayers completely or partially surround a sub-pixel electrode within aconfinement well.

Referring now to FIG. 7, a cross-sectional view of yet another exemplaryembodiment is illustrated. OLED display 500 can include surface feature516 and a definition layer 514. The arrangement of FIG. 7 is similar tothat described above with reference to FIG. 4, with like numbers used torepresent like elements except using the 500 series as opposed to the200 series. As illustrated in FIG. 7, however, OLED display 500 furtherincludes a definition layer 514 disposed under confinement structures504. The definition layer 514 can be any physical structure used todefine portions of OLED display 500. In an embodiment, definition layer514 can be a definition layer that can be any physical structure used todelineate pixels within the pixel array and/or sub-pixels with a pixel.As illustrated, in an exemplary embodiment, the definition layer 514 canextend beyond the confinement structure 504 and over a portion ofelectrodes 506, 508. Definition layer 514 can be made of an electricallyresistant material such that the definition layer 514 prevents currentflow and thus can reduce unwanted visual artifacts by preventing lightemission through the edges of the sub-pixel. In this way, definitionlayer 514 can assist in masking film layer non-uniformities formed atthe edge of each sub-pixel that may occur due to edge drying effects.The hole conducting layer 510 and the organic light-emissive layer 512can be deposited (as previously discussed, for example, with referenceto FIGS. 3A and 3B) such that layers 510, 512 sufficiently conform tounderlying surface feature topographies and have a substantially uniformthickness, as has been described above.

Those having ordinary skill in the art would appreciate that the variousarrangements and structures, e.g. surface features, definition layers,etc., are exemplary only and that various other combinations andarrangements may be envisioned and fall within the scope of the presentdisclosure.

Referring now to FIGS. 8-11, partial cross-sectional views of thesubstrate exhibiting various exemplary steps during an exemplary methodof manufacturing an OLED display 600 are illustrated. While the methodof manufacturing will be discussed below with reference to display 600,any and/or all of the steps described can be used in manufacturing otherOLED displays, for example OLED displays 100, 200, 300, 400, and 500described above. As illustrated in FIG. 8, electrodes 606, 608 andsurface features 616 can be provided over substrate 602. The electrodes606, 608 and surface features 616 can be formed using any manufacturingmethod such as inkjet printing, nozzle printing, slit coating, spincoating, vacuum thermal evaporation, sputtering (or other physical vapordeposition method), chemical vapor deposition, etc., and any additionalpatterning not otherwise included in the deposition technique can beachieved by using shadow masking, photolithography (photoresist coating,exposure, development, and stripping), wet etching, dry etching,lift-off, etc. The electrodes 606, 608 can be formed simultaneously withsurface features 616 or sequentially with either the electrodes or thesurface features being formed first.

Definition layer 614 and additional definition layer 618 can then bedeposited over the surface features 616 and electrodes 606, 608, asillustrated in FIG. 9. Layers 614 and 618 can be formed using anymanufacturing method, such as inkjet printing, nozzle printing, slitcoating, spin coating, vacuum thermal evaporation, sputtering (or otherphysical vapor deposition method), chemical vapor deposition, etc., andany needed additional patterning not otherwise included in thedeposition technique can be achieved by using shadow masking,photolithography (photoresist coating, exposure, development, andstripping), wet etching, dry etching, lift-off, etc. Definition layer614 can be formed simultaneously with additional definition layer 618 orthe layers 614, 618 can be formed sequentially with either layer 614 or618 being formed first.

Confinement structures 604 are provided over definition layers 614. Theconfinement structures 604 can be formed to define confinement wells 620that surround a plurality of sub-pixel electrodes 606, 608 whilespanning a plurality of pixels. The confinement structures 604 can beformed using any manufacturing method, such as inkjet printing, nozzleprinting, slit coating, spin coating, vacuum thermal evaporation,sputtering (or other physical vapor deposition method), chemical vapordeposition, etc., and any additional patterning not otherwise includedin the deposition technique can be achieved by using shadow masking,photolithography (photoresist coating, exposure, development, andstripping), wet etching, dry etching, lift-off, etc. In one exemplarytechnique, as illustrated in FIG. 10, confinement structure material canbe deposited over substrate 602 in a continuous layer 604′ and the layercan then be patterned using a mask 607 such that a portion 605 of layer604′ can be removed to expose the sub-pixel electrodes 606, 608. Theconfinement structures 604 are formed by the material of layer 604′remaining after portions 605 are removed. Alternatively, confinementstructures 604 can be formed by actively depositing material to formonly the confinement structure such that the deposited confinementstructure 604 can define boundaries and the confinement wells are formedwithin the boundaries of the deposited confinement structures 604.

In an exemplary embodiment, as illustrated in FIG. 10, each confinementwell can include a plurality of active sub-pixel regions including W1and W2 separated by gap S. As above, the dimensions, W1, W2, and CW areprimarily related to the pixel pitch. And the dimension of the gap S isrelated to restrictions associated with fabrication techniques andprocessing, and layout, and may range from 1 μm to even greater than 10μm, with 3 μm being an exemplary minimum dimension. The dimensions SB1and SB2 associated with the extension of the definition layer inside theedge of the confinement well can be selected as desired. However, alarger dimension will contribute to a reduction in fill factor byreducing the amount of available active pixel electrode area. Therefore,it may be desirable to select the minimum dimension that will serve thedesired function, which is generally to exclude edge non-uniformitiesfrom the active electrode area. In various exemplary embodiments, thisdimension can range from 1 μm to 20 μm, and may for example range from 2μm to 5 μm.

As illustrated in FIG. 11, a hole conducting layer 610 can then bedeposited using inkjet printing within the confinement well 620. Forexample, inkjet nozzle 650 can direct droplet(s) 651 of hole conductingmaterial within a target area defined within the confinement well 620.The hole conducting layer 610 may further comprise two discrete layers,for example, a hole injection layer and a hole transporting layer, andthese layers can be sequentially deposited by an inkjet method asdescribed herein. In addition, organic light-emissive layer 612 can bedeposited using inkjet printing within the confinement well 620 over thehole conducting layer 610. Inkjet nozzle 650 can direct droplet(s) 651of organic light-emissive material within a target area over the holeconducting layer 610. One of ordinary skill in the art would appreciatethat while a single nozzle is discussed with reference to FIG. 11,multiple nozzles can be implemented to provide droplets containing holeconducting material or organic light-emissive material within aplurality of confinement wells. As those of ordinary skill in the artare familiar with, in some embodiments, the same or differing colors oforganic light-emissive material can be deposited from multiple inkjetnozzle heads simultaneously. In addition, droplet ejection and placementon the target substrate surface can be performed using technology knownto those of ordinary skill in the art.

In an exemplary embodiment, a single organic light-emissive layer 612can be deposited within confinement well 620 such as a red, green, orblue layer. In an alternative exemplary embodiment, a plurality oforganic light emissive layers can be deposited within confinement well620, one over the other. Such an arrangement can work, for example, whenthe light emissive layers have differing light emissive wavelengthsranges such that when one light emissive layer is activated to emitlight, the other light emissive layer does not emit light or interferewith the light emission of the first organic light-emissive layer. Forexample, a red organic light-emissive layer or a green organiclight-emissive layer can be deposited within confinement well 620 andthen a blue organic light-emissive layer can be deposited over the redor green organic light-emissive layer. In this way, while a confinementwell can include two different light-emissive layers, only one lightemissive-layer is configured to emit light within the confinement well.

Layers 610 and 612 can be deposited so as to sufficiently conform to thetopography of definition layer 614, surface structure 616, additionaldefinition layer 618, and electrodes 606, 608, as has been describedabove, and can have a substantially uniform thickness as describedabove.

The various aspects described above with reference to FIGS. 3A-11 can beused for a variety of pixel and sub-pixel layouts in accordance with thepresent disclosure, with FIG. 2 being one exemplary and nonlimiting suchlayout. Various additional exemplary layouts contemplated by the presentdisclosure are depicted in FIGS. 12-18. The various exemplary layoutsillustrate that there are many ways to implement the exemplaryembodiments described herein; in many cases, the selection of anyparticular layout is driven by various factors, such as, for example,the underlying layout of the electrical circuitry, a desired pixel shape(which are depicted as rectangular and hexagonal shape in theillustrated embodiments, but can be other shapes as well, such aschevrons, circles, hexagons, triangles, and the like), and factorsrelated to visual appearance of the display (such as visual artifactsthat can be observed for differing configurations and for differingtypes of display content, such as text, graphics, or moving video).Those having ordinary skill in the art would appreciate that a number ofother layouts fall within the scope of the present disclosure and can beobtained through modification and based on the principles describedherein. Further, those having ordinary skill in the art would understandthat although for simplicity only the confinement structures that definethe confinement wells are described below in the descriptions of FIGS.12-18, any of the features, including surface features, circuitry, pixeldefinition layers, and other layers, described above with reference toFIGS. 3A-11 can be used in combination with any of the pixel layoutsherein.

FIG. 12 depicts a partial plan view of an exemplary embodiment of pixeland sub-pixel layout for an OLED display 700, and is similar to thelayout of FIG. 2 with further aspects of the layout being describedbelow. A confinement structure 704, for example, a bank structure, asdiscussed above can be provided on a substrate to define a plurality ofconfinement wells 720, 730, 740 in an arrayed configuration. Eachconfinement well 720, 730, 740 can include a substantially continuouslayer of OLED material (indicated by the shaded regions) such that theorganic layer extends through the confinement well 720, 730, 740 to theconfinement structure 704 surrounding the confinement well, for example,edges of the layer of OLED material in each well 720, 730, 740 maycontact the confinement structure 704. OLED layers can include, forexample, one or more of hole injecting materials, hole transportingmaterials, electron transporting materials, electron injectingmaterials, hole blocking materials, and organic light emissive materialsproviding for emission of differing light-emissive wavelength ranges.For example, confinement well 720 can include an organic light-emissivelayer associated with light emission within the red wavelength range andis indicated by R, confinement well 730 can include an organiclight-emissive layer associated with light emission within the greenwavelength range indicated by G, and confinement well 740 can include anorganic light-emissive layer associated with light emission within theblue wavelength range indicated by B. The wells 720, 730, 740 can have avariety of arrangements and configurations, including with respect toeach other (e.g., layouts). For example, as illustrated in FIG. 12,confinement wells 720 and confinement wells 730 that respectivelycontain red organic light-emissive layer R and green organiclight-emissive layer G are disposed in rows R₁, R₃ in an alternatingarrangement. Alternating with the rows R₁ and R₃ are rows R₂, R₄ of theconfinement wells 740 that contain blue organic-light emissive layer B.Confinement wells 720, 730 also can be alternatively arranged within therows R₁, R₃.

A plurality of electrodes 706, 707, 708, 709; 736, 737, 738, 739; and742, 744 can be disposed in each confinement well 720, 730, 740,respectively, wherein each electrode can be associated with a sub-pixelassociated with a particular light emission color such as red, green, orblue light emission. A pixel 750, 751, 752, 753, identified in FIG. 12by dashed lines, can be defined to include one sub-pixel having redlight emission, one sub-pixel having green light emission, and onesub-pixel having blue light emission. For example, each confinement well720, 730, 740 can respectively include a plurality of electrodes 706,707, 708, 709; 736, 737, 738, 739; and 742, 744 configured such thattheir associated electrode active regions correspond to the electrodeoutlines shown in FIG. 12, are spaced apart from each other. Confinementwells 720, 730, 740 can have a differing number and/or arrangement ofelectrodes within the confinement well. Alternatively, additionalarrangements are possible, such as arrangements with other sets ofcolors than red, green, and blue, including combinations of colorsinvolving more than three sub-pixel colors. Other arrangements are alsopossible in which more than one sub-pixel of a single color isassociated with a particular pixel, for example, each pixel can haveassociated with it one red, one green, and two blue sub-pixels, or othercombinations of numbers of sub-pixels of a particular color and othercombinations of colors. Moreover, if multiple layers of differinglight-emissive material are positioned over each other, it iscontemplated that differing color sub-pixels may overlap each other. Asillustrated in FIG. 12, sub-pixel electrodes can be spaced apart fromstructures that define the confinement wells. In an alternativeembodiment, the sub-pixel electrodes can be deposited such that they aredirectly adjacent to the confinement well structures such that no gapoccurs between the electrode and the confinement structure. In addition,the confinement well structures can be disposed over a portion of thesub-pixel electrodes.

In addition, adjacent confinement wells can have differing sub-pixelarrangements. For example, as illustrated in FIG. 12, confinement wells720 and 730 include a 2×2 active electrode region arrangement, andconfinement well 740 includes a 1×2 active electrode region arrangement,with the active electrode regions in the 2×2 arrangements being squaresof the same size and the active electrode regions in the 1×2 arrangementbeing rectangles of the same size. As noted above, electrodes withindiffering confinement wells can have differing surface areas of activeregions.

In one exemplary arrangement, the active regions associated with theelectrodes used to address sub-pixels of light-emission within the bluewavelength range B can have a greater surface area than the activeregions associated with the electrodes used to address light-emissionwithin the red and/or green wavelength range R, G. It may be desirablefor the active regions of the electrodes associated with the sub-pixelshaving light-emission in the blue wavelength range B to have a greatersurface area than the active regions associated with a sub-pixelelectrode associated with a red or green light emission becausesub-pixels associated with blue light emission often have substantiallyshorter lifetimes than sub-pixels associated with having red or greenlight emission when operating at the same area brightness levels.Increasing the relative active area of the sub-pixels associated withblue light emission enables operation at relatively lower areabrightness levels while still maintaining the same overall displaybrightness, thereby increasing the lifetime of the sub-pixels associatedwith blue light emission and the overall lifetime of the display. It isnoted that sub-pixels associated with red and green light emission maybe correspondingly reduced in relation to the sub-pixel associated withblue light emission. This can lead to the sub-pixels associated with redand green light-emission to be driven at a higher brightness level inrelation to a sub-pixel associated with blue light-emission which canreduce the red and green OLED device lifetime. However, the lifetimes ofthe sub-pixels associated with red and green light emission can besignificantly longer than the lifetime associated with the sub-pixelassociated with the blue sub-pixel that the sub-pixel associated withthe blue light emission remains the limiting sub-pixel with respect tothe overall display lifetime. While the active regions of the electrodeswithin confinement well 740 are illustrated as being arranged with theirelongate direction extending horizontally in FIG. 12, the electrodescould alternatively be arranged such that their elongate directionextends vertically in FIG. 12.

Intervals between adjacent confinement wells can be equal throughout thepixel layout or can vary. For example, with reference to FIG. 12, aninterval b′ between confinement wells 720, 730 can be greater than orequal to the interval f′ between confinement wells 720 or 730 and 740.In other words, the horizontal interval between adjacent confinementwells in a row may differ from the vertical interval between adjacentconfinement wells in adjacent rows, in the orientation of FIG. 12.Moreover, the horizontal interval b′ in rows R₁, R₃ may be equal to ordiffer from the horizontal interval a′ in R₂, R₄.

Spacing (gaps) between the active regions of the electrodes within eachof the differing confinement wells 720, 730, 740 also can be the same ordiffer and may vary depending on the direction of spacing (e.g.,horizontal or vertical). In one exemplary embodiment, the gaps d and ebetween the active regions of the electrodes within the confinementwells 720, 730 can be the same and can differ from the gap betweenactive regions of the electrodes within the confinement well 740.Further, in various exemplary embodiments, the gaps between adjacentactive electrode regions within a confinement well are less than thegaps between adjacent active electrode regions in neighboringconfinement wells, either in the same or differing rows. For example, c,d, and e may each be less than either a, b, or fin FIG. 12.

In FIG. 12 there is shown a gap between the interior edges of eachconfinement well, e.g. 720, and the exterior edges of each of the activeelectrode regions associated within that confinement well, e.g. 706,707, 708, 709. However, as illustrated in FIG. 2, according to variousexemplary embodiments, such a gap may not be present and the exterioredge of each of active electrode regions may be the same as the interioredge of the confinement well. This configuration can be achieved, forexample, using a structure like the one illustrated in FIG. 3A, wherethe configuration show in FIG. 12, in which such a gap is present, canbe achieved, for example, using a structure like the one illustrated inFIG. 5A. However, other structures may also be able to achieve the sameconfigurations illustrated in FIGS. 2 and 12.

Pixels 750, 751, 752, 753 can be defined based on the confinement wellarrangement and corresponding sub-pixel layout. The overall spacing, orpitch, of pixels 750, 751, 752, 753 can be based on the resolution ofthe display. For example, the higher the display resolution, the smallerthe pitch. In addition, adjacent pixels can have differing sub-pixelarrangements. For example, as illustrated in FIG. 12, pixel 750 includesa red sub-pixel R in the top left portion, a green sub-pixel G in thetop right portion, and a blue sub-pixel B in spanning the majority ofthe bottom portion of the pixel. The sub-pixel layout of pixel 751 issimilar to that of pixel 750 except the relative positions of the greensub-pixel G and the red sub-pixel R being switched, with the greensub-pixel G in the top left portion, a red sub-pixel R in the top rightportion. Pixels 752 and 753, which are adjacent and underneath pixels751, 750 respectively, are mirror images of pixels 751 and 750,respectively. Thus, pixel 752 includes a blue sub-pixel B in the topportion, a green sub-pixel G in the bottom left portion, and a redsub-pixel R in the bottom right portion. And pixel 753 includes a bluesub-pixel in the top portion, a green sub-pixel in the bottom leftportion, and a red sub-pixel in the bottom right portion.

In an exemplary embodiment for a high resolution display according toFIG. 12 and having 326 pixels per inch (ppi), a pixel including a redsub-pixel, a green sub-pixel, and a blue sub-pixel can have overalldimensions of approximately 78 μm×78 μm, corresponding to the overallpitch of the display needed to achieve 326 ppi. Assuming for thisembodiment that a′=b′=f′=12 μm, reflecting, as previously discussed, thestate of the art minimum spacing between confinement regions, furtherassuming that a=b=f=12 μm+6 μm=18 μm, reflecting a case in which adefinition layer is utilized that extends 3 μm inside the confinementwell edge, and finally assuming c=d=e=3 μm as a typical gap betweenelectrode active regions within a confinement well, the areas associatedwith each of the red and green sub-pixels can be 28.5 μm×28.5 μm and thearea associated with the blue sub-pixels can be 60 μm×27 μm. The surfacearea of the blue sub-pixels can be greater than each of the red andgreen sub-pixels to increase overall display lifetime as describedabove. Such a layout can have confinement wells associated withgroupings of 2×2 red and green sub-pixels having dimensions of 66 μm×66μm, and confinement wells associated with groupings of 1×2 bluesub-pixels having dimensions of 66 μm×66 μm. Such dimensions provide forstraightforward loading of active OLED material with conventional inkjetprint heads and printing systems while also providing for a highresolution display with high fill factor of greater than 50%, such as53%. Such dimensions also provide for such features in a structurehaving a definition layer that can provide for enhanced film uniformitywithin the active electrode region by blocking current flow through thefilm region immediately adjacent to the confinement well wall.

In a corresponding exemplary embodiment for a high resolution displayhaving 440 pixels per inch (ppi) a pixel including a red sub-pixel, agreen sub-pixel, and a blue sub-pixel can have an overall dimension ofapproximately 58 μm×58 μm where assuming the same value for thedimensions a, b, c, d, e, f, a′, b′, and f′ as in the immediatelyprevious example, the area associated with each of the red and greensub-pixels can be 18.5 μm×18.5 μm and the area associated with the bluesub-pixels can be 40 μm×17 μm. The surface area of the blue sub-pixelscan be greater than each of the red and green sub-pixels to increaseoverall display lifetime as described above. Such a layout can haveconfinement wells associated with groupings of 2×2 red and greensub-pixels having dimensions of 46 μm×46 μm, and confinement wellsassociated with groupings of 1×2 blue sub-pixels having dimensions of 46μm×46 μm. Such dimensions provide for relatively straightforward loadingof active OLED material with conventional inkjet print heads andprinting systems while also providing for a high resolution display withhigh fill factor of 40%.

In each of the above exemplary embodiments, various values for thedimensions a, b, c, d, e, f, a′, b′, f′ can be implemented. However, oneof ordinary skill in the art would recognize that these dimensions vary.For example, the spacing between confinement walls (a′, b′, f′) can bevaried, as previously discussed from as little as 1 μm to as large ashundreds of microns for large ppi. The gap between active electroderegions within a confinement well (c, d, e) can vary, as discussedabove, from as little as 1 μm to as large as tens of microns. The gapbetween the active electrode regions and the edge of the confinementwalls (effectively half the difference between a′ and a, b′ and b′ andf′ and f, respectively) can also vary, as discussed above, from aslittle as 1 μm to as large as 10 μm. Furthermore, as these dimensionsare varied, they apply constraints, along with the ppi (that determinesthe overall pitch of the display), that limit the range of valuesallowed for the confinement well dimensions and the active electroderegions contained therein. In the above exemplary embodiments, forsimplicity, square confinement wells of the same dimension are used forall three colors. However, the confinement wells need not be square, andneed not all be the same size. In addition, the dimensions provided forin FIG. 12 indicate various common dimensions, for example, the gapbetween active electrode regions within the red confinement wells andthe green confinement wells, but in some exemplary embodiments, thosegaps are not common dimensions but differ from each other.

FIG. 13 depicts a partial plan view of another exemplary pixel/sub-pixellayout of an OLED display 800. Features common to previously discussedexemplary embodiments are not described. For simplicity, differenceswill be discussed.

Display 800 can have a greater separation between the active regionsassociated with sub-pixel electrodes within a confinement well than forexample, sub-pixel electrodes of display 700 as illustrated in FIG. 12.Spacing between adjacent active regions associated with electrodes 806,807, 808, 809; 836, 837, 838, 839; and 842, 844 within respectiveconfinement wells 820, 830, 840 can be greater than an interval betweenadjacent active electrode regions in adjacent confinement wells. Forexample, the active regions associated with electrode 836 can be spacedapart from one another a predetermined distance g, and similarly for theactive regions associated with electrode 838. The interval k betweenadjacent active electrode regions in neighboring confinement wells 820,830 can be less than the interval g between the active regionsassociated with electrodes 836, 838, and the interval m between theactive regions associated with electrode 842 (and similarly forelectrode 844) can be greater than the interval n between the adjacentactive electrode regions in neighboring confinement well 840 andconfinement wells 820, 830. Such spacing can provide for greater spacingbetween sub-pixel electrodes disposed within a confinement well andassociated with the same light emission color while providing for acloser arrangement of sub-pixel electrodes associated with a singledefined pixel. This spacing can reduce undesirable visual artifacts suchthat the display appears to be an array of closely arranged RGB tripletsand not an array of closely arranged RRRR quadruplets, GGGG quadruplets,and BB pairs.

Another exemplary pixel/sub-pixel layout for a display in accordancewith the present disclosure is depicted in FIG. 14. A confinementstructure 904 can be provided on a substrate to define a plurality ofconfinement wells 920, 930, 940 in an arrayed configuration. Eachconfinement well 920, 930, 940 can include a substantially continuouslayer of OLED material (indicated by the shaded regions) such that edgesof the organic layer extends throughout the confinement well 920, 930,940 to the confinement structure 904 surrounding the confinement well,for example, edges of the layer of OLED material in each well 920, 930,940 may contact the confinement structure 904. Active OLED layers caninclude, for example, without limitation, one or more of hole injectingmaterials, hole transporting materials, electron transporting materials,electron injecting materials, hole blocking materials, and organic lightemissive materials providing for emission of differing light-emissivewavelength ranges. For example, confinement well 920 can include anorganic light-emissive layer associated with light-emission within thered wavelength ranges range R, confinement well 930 can include anorganic light-emissive layer associated with light-emission within thegreen wavelength range G, and confinement well 940 can include anorganic light-emissive layer associated with light-emission within theblue wavelength range B. The organic light-emissive layers can bedisposed within the wells in any arrangement and/or configuration. Forexample, the organic light-emissive layers disposed in confinement wells920, 930, 940 are arranged having an alternating arrangement within eachrow. Adjacent rows can have the same arrangement or differingarrangement. In addition, while the adjacent rows of confinement wells920, 930, 940 are illustrated as having a uniform alignment, adjacentrows of confinement wells 920, 930, 940 can alternatively have anon-uniform alignment such as an offset arrangement. Moreover,confinement wells 920 and 930 can be reversed in the alternativepattern.

The configuration of each well 920, 930, 940 can have a rectangularshape such that each well is elongated in a vertical direction. Wells920, 930, 940 can have approximately the same dimensions in theelongated vertical direction. In addition, wells 920, 930, 940 can haveapproximately the same width. However, the entire well 940 associatedwith a blue organic light-emissive layer can correlate to a singlesub-pixel and thus pixel, while wells 920, 930 associated with the redand green organic light-emissive layer can correlate to a plurality ofsub-pixels and thus a plurality of pixels. For example, confinementwells 920, 930 can include a plurality of electrodes such that eachelectrode is associated with a differing sub-pixel of a differing pixel.As illustrated in FIG. 14, well 920 includes two electrodes 926, 928 andis associated with two differing pixels 950, 951.

A differing number of electrodes 926, 928, 936, 938, 946 can be disposedwithin differing confinement wells. For example, some confinement wells920, 930 can include a plurality of electrodes 926, 928; and 936, 938 soas to selectively address electrodes disposed in the same confinementwell but produce light emission for differing sub-pixels in differingpixels, while other confinement wells 940 only include one electrode 946to address an electrode disposed in one confinement well associated withone pixel. Alternatively, the number of electrodes disposed inconfinement well 940 can be half of the number of electrodes disposed inother confinement wells 920, 930. In addition, electrodes withindiffering confinement wells can have differing surface areas. Forexample, electrodes associated with light-emission within the bluewavelength range can have a greater surface area than electrodesassociated with light-emission within the red and/or green wavelengthrange to improve the life of display 900 and reduce power consumption.

Pixels 950, 951 can be defined based on the confinement well arrangementand corresponding sub-pixel layout. The overall spacing, or pitch, ofpixels 950, 951 can be based on the resolution of the display. Forexample, the higher the display resolution, the smaller the pitch. Inaddition, adjacent pixels can have differing pixel arrangements. Forexample, as illustrated in FIG. 14, pixel 950 can include a greensub-pixel G on the left, a blue sub-pixel B in the middle, and a redsub-pixel R on the right. Pixel 951 can include a red sub-pixel R on theleft, a blue sub-pixel B in the middle and a green sub-pixel G on theright.

FIG. 15 depicts a partial plan view of an exemplary embodiment of apixel and sub-pixel layout for an OLED display 1000. Features common toembodiments discussed above are not described (though similar labels canbe found with a 1000 series in FIG. 15). For simplicity, differenceswill be discussed. Confinement structure 1004 can be configured todefine a plurality of wells 1020, 1030, 1040. Wells 1020, 1030, 1040 canbe arranged such that wells 1020, 1030, 1040 are aligned in uniform rowswhere wells associated with red light emission and green light emission(for example 1020, 1030) alternate within a single row and wellsassociated with blue light emission (for example 1040) are within asingle row. In addition, wells 1020, 1030, 1040 can be configured suchthat the wells 1020, 1030, 1040 are aligned within a uniform column suchthat columns of wells 1020, 1040 alternate with columns of wells 1030,1040. Confinement wells 1020 and 1030 can be alternatively arranged suchthat confinement wells 1030 begin the alternating pattern.

Each confinement well 1020, 1030, 1040 can be approximately the samesize. However, the number of electrodes associated with each well 1020,1030, 1040 can differ. For example, as illustrated in FIG. 15, the wellassociated with red light emission 1020 can include electrodes 1026,1027, 1028, 1029, the well associated with green light emission 1030 caninclude electrodes 1036, 1037, 1038, 1039, and the well associated withblue light emission 1040 can include electrodes 1046, 1048. Whileelectrodes within confinement well 1040 are illustrated as beingarranged horizontally spaced, the electrodes could alternatively bearranged so as to be vertically spaced.

While electrodes 1026, 1027, 1028, 1029, 1036, 1037, 1038, 1039 areillustrated in FIG. 15 as having a square shape and electrodes 1046,1048 are illustrated as having a rectangular shape, electrodes havingany shape are contemplated as within the scope of the present disclosuresuch as, for example, circular, chevrons, hexagonal, asymmetrical,irregular curvature, etc. A plurality of differing shapes of electrodescould be implemented within a single confinement well. In addition,differing confinement wells can have differing shaped electrodes. Thesize and shape of the electrode can influence the distance between theelectrodes and thus the overall layout of the display. For example, whenthe shapes are complementary, electrodes can be spaced closer togetherwhile still maintaining electrical isolation between adjacentelectrodes. In addition, the shape and spacing of the electrodes caninfluence the degree of visual artifacts created. Electrode shapes canbe selected to reduce undesired visual artifacts and enhance imageblending to produce a continuous image.

Pixels 1050, 1051, shown in dashed lines, can be defined based on basedon the confinement well arrangement and corresponding sub-pixel layout.The overall spacing, or pitch, of pixels 1050, 1051 can be based on theresolution of the display. For example, the higher the displayresolution, the smaller the pitch. In addition, pixels can be defined ashaving an asymmetrical shape. For example, as illustrated in FIG. 15,pixel 1050, 1051 can have an “L” shape.

FIG. 16 depicts a partial plan view of an exemplary embodiment of apixel and sub-pixel layout for an OLED display 1100. Features common toexemplary embodiments discussed above will not be described (thoughsimilar labels with an 1100 series can be found in FIG. 16). Confinementstructure 1104 can be configured to define a plurality of confinementwells 1120, 1130, 1140 in a plurality of columns C₁, C₂, C₃, C₄. ColumnsC₁, C₂, C₃, C₄, can be arranged to produce a staggered arrangement. Forexample, the confinement wells in columns C₁, and C₃ can be offset fromcolumns C₂ and C₄, producing a staggered row arrangement whilemaintaining a uniform column arrangement. Pixels 1150, 1151 can bedefined based on the pitch of the confinement well arrangement. Thepitch of the confinement well arrangement can be based on the resolutionof the display. For example, the smaller the pitch the higher thedisplay resolution. In addition, pixels can be defined as having anasymmetrical shape. For example, as illustrated in FIG. 16 by the dashedlines, pixel 1150, 1151 can have a non-uniform shape.

FIG. 17 depicts a partial plan view of an exemplary embodiment of apixel and sub-pixel layout for an OLED display 1200. Features common toembodiments discussed above are not described (though similar labelswith a 1200 series can be found in FIG. 17). As illustrated in FIG. 17,confinement structure 1204 can be configured to define a plurality ofconfinement wells 1220, 1230, 1240. Each confinement well 1220, 1230,1240 can have a differing area. For example, the well 1220 associatedwith red light emission R can have an area greater than the well 1230associated with the green light emission G. In addition, confinementwells 1220, 1230, 1240 can be associated with a differing number ofpixels. For example, confinement well 1220 can be associated with pixels1251, 1252, 1254, 1256 and confinement wells 1230, 1240 can beassociated with pixels 1251, 1252. Wells 1220, 1230, 1240 can beconfigured in uniform rows R₁, R₂, R₃, R₄, R₅. Rows R₂, R₃, and R₅ canbe associated with blue light emission wells 1240 and rows R₁ and R₄ canbe associated with alternating red light emission wells 1220 and greenlight emission wells 1230. The confinement structure 1204 can have avariety of dimensions D₁, D₂, D₃, D₄. For example, D₁ can be greaterthan D₂, D₃, or D₄, D₂ can be less than D₁, D₃, or D₄, and D₃ can beapproximately equal to D₄.

FIG. 18 depicts a partial plan view of an exemplary embodiment of apixel and sub-pixel layout for an OLED display 1300. Features common toembodiments discussed above, for example FIG. 17, are not described(though similar labels with a 1300 series can be found in FIG. 18).Confinement structure 1304 can be configured to define a plurality ofconfinement wells 1320, 1330, 1340. Wells 1320, 1330, 1340 can bearranged such that wells associated with red light emission 1320 andgreen light emission 1330 can be alternated within a row with wellsassociated with blue light emission 1340.

While various pixel and sub-pixel layouts are described above, theexemplary embodiments in no way limit the shape, arrangement, and/orconfiguration of confinement wells that span a plurality of pixels asdescribed. Instead, confinement wells associated with the presentdisclosure in combination with inkjet printing manufacturing methodsallow for flexible pixel layout arrangements to be selected.

Various pixel layouts are contemplated that can enable a high resolutionOLED display using inkjet printing. For example, as illustrated in FIG.19, confinement structures 1404 can create a hexagonal pattern such thata pixel 1450 can comprise a confinement well 1420 associated with redemission R, a confinement well 1430 associated with green emission G,and a confinement well 1440 associated with blue emission B. Due to thepitch, the shape of the confinement wells, and the ability to pack theconfinement wells closer together, an OLED display having highresolution can be created using inkjet printing.

Using various aspects in accordance with exemplary embodiments of thepresent disclosure, some exemplary dimensions and parameters could beuseful in attaining high resolution OLED displays with an increased fillfactor. Tables 1-3 include conventional dimensions and parameters aswell as prophetic, non-limiting examples in accordance with exemplaryembodiments of the present disclosure associated with an OLED displayhaving a resolution of 326 ppi where Table 1 describes a sub-pixelassociated with red light-emission, Table 2 describes a sub-pixelassociated with green light-emission, and Table 3 describes a sub-pixelassociated with blue light-emission. Tables 4-6 include conventionaldimensions and parameters as well as prophetic, non-limiting examples inaccordance with exemplary embodiments of the present disclosureassociated with a display having a resolution of 440 ppi where Table 4describes a sub-pixel associated with red light-emission, Table 5describes a sub-pixel associated with green light-emission, and Table 6describes a sub-pixel associated with blue light emission.

TABLE 1 Length Width Area of For a sub-pixel associated with of Sub- ofSub- Confinement red emission in display having pixel pixel Wellresolution of 326 ppi (μm) (μm) (μm²) Conventional sub-pixel 65.9 10.5690.7 Sub-pixel associated with 31.5 31.5 989.5 Confinement Structure asillustrated in FIGS. 3A, 3B Conventional sub-pixel with Pixel 59.9 9.0537.9 Definition Layer Sub-pixel associated with 28.5 28.5 809.8Confinement Structure with definition layer as illustrated in FIGS. 5A,5B

TABLE 2 Length Width Area of For a sub-pixel associated with of Sub- ofSub- Confinement green emission in display having pixel pixel Wellresolution of 326 ppi (μm) (μm) (μm²) Conventional sub-pixel 65.9 10.5690.7 Sub-pixel associated with 31.5 31.5 989.5 Confinement Structure asillustrated in FIGS. 3A, 3B Conventional sub-pixel with 59.9 9.0 537.9Pixel Definition Layer Sub-pixel associated with 28.5 28.5 809.8Confinement Structure with definition layer as illustrated in FIGS. 5A,5B

TABLE 3 Length Width Area of For a sub-pixel associated with of Sub- ofSub- Confinement blue emission of a display having pixel pixel Wellresolution of 326 ppi (μm) (μm) (μm²) Conventional sub-pixel 65.9 21.01381.4 Sub-pixel associated with 30.0 65.9 1979.1 Confinement Structureas illustrated in FIGS. 3A, 3B Conventional sub-pixel with 59.9 18.01075.9 Pixel Definition Layer Sub-pixel associated with 27.0 59.9 1619.6Confinement Structure with definition layer as illustrated in FIGS. 5A,5B

TABLE 4 Length Width Area of For a sub-pixel associated with of Sub- ofSub- Confinement red emission of a display having pixel pixel Wellresolution of 440 ppi (μm) (μm) (μm²) Conventional sub-pixel 45.7 5.4248.4 Sub-pixel associated with 21.4 21.4 456.4 Confinement Structure asillustrated in FIGS. 3A, 3B Conventional sub-pixel with 39.7 3.9 159.2Pixel Definition Layer Sub-pixel associated with 18.4 18.4 337.2Confinement Structure with definition layer as illustrated in FIGS. 5A,5B

TABLE 5 Length Width Area of For a sub-pixel associated with of Sub- ofSub- Confinement green emission of a display having pixel pixel Wellresolution of 440 ppi (μm) (μm) (μm²) Conventional sub-pixel 45.7 5.4248.4 Sub-pixel associated with 21.4 21.4 456.4 Confinement Structure asillustrated in FIGS. 3A, 3B Conventional sub-pixel with Pixel 39.7 3.9156.2 Definition Layer Sub-pixel associated with 18.4 18.4 337.2Confinement Structure with definition layer as illustrated in FIGS. 5A,5B

TABLE 6 Length Width Area of For a sub-pixel associated with of Sub- ofSub- Confinement blue emission of a display having pixel pixel Wellresolution of 440 ppi (μm) (μm) (μm²) Conventional sub-pixel 45.7 10.9496.8 Sub-pixel associated with 20.0 45.7 912.8 Confinement Structure asillustrated in FIGS. 3A, 3B Conventional sub-pixel with 39.7 7.9 312.4Pixel Definition Layer Sub-pixel associated with 17.0 39.7 674.4Confinement Structure with definition layer as illustrated in FIGS. 5A,5B

Table 7 includes conventional dimensions and parameters as well asprophetic, non-limiting examples in accordance with exemplaryembodiments of the present disclosure associated with a pixel within adisplay having a resolution of 326 ppi where the pixel includes a redsub-pixel, a green sub-pixel, and a green sub-pixel.

TABLE 7 Active Total Area of Area of For a display having resolution ofPixel Pixel 326 ppi (μm²) (μm) Fill Factor * Conventional Confinement2762.7 6070.6 46% Structure Confinement Structure as 3958.2 6070.6 65%illustrated in FIGS. 3A, 3B Conventional Confinement 2151.8 6070.6 35%Structure with Pixel Definition Layer Confinement Structure with 3239.26070.6 53% definition layer as illustrated in FIGS. 5A, 5B * (ActiveArea/Total Area) rounded up to the nearest percentage point

As illustrated in Table 7 above, it is contemplated that variousexemplary embodiments in accordance with the present disclosure canachieve a fill factor improvement over conventional confinementstructures. For example, a fill factor for a display that contemplates aconfinement structure illustrated in FIGS. 3A and 3B can increase thefill factor by about 43% over a conventional structure, therebyachieving a total fill factor of 65%. In another embodiment, a fillfactor for a display that contemplates a confinement structure asillustrated in FIGS. 5A and 5B can improve the fill factor by about 51%over a conventional structure thereby achieving a total fill factor of53%.

Table 8 includes conventional dimensions and parameters as well asprophetic, non-limiting examples in accordance with exemplaryembodiments of the present disclosure associated with a pixel within adisplay having a resolution of 440 ppi where the pixel includes a redsub-pixel, a green sub-pixel, and a green sub-pixel.

TABLE 8 Active Total Area of Area of For a display having resolutionPixel Pixel of 440 ppi (μm²) (μm) Fill Factor * Conventional Confinement993.5 3332.4 30% Structure Confinement Structure as 1825.6 3332.4 55%illustrated in FIGS. 3A, 3B Conventional Confinement 624.8 3332.4 19%Structure with Pixel Definition Layer Confinement Structure with 1348.93332.4 40% definition layer as illustrated in FIGS. 5A, 5B * (ActiveArea/Total Area) rounded up to the nearest percentage point

As illustrated in Table 8 above, it is contemplated that variousexemplary embodiments in accordance with the present disclosure canachieve a fill factor improvement over conventional confinementstructures. For example, a fill factor for a display that contemplates aconfinement structure illustrated in FIGS. 3A and 3B can improve thefill factor by about 84% over conventional structure thereby achieving atotal fill factor of 55%. In another embodiment, a fill factor for adisplay that contemplates a confinement structure as illustrated inFIGS. 5A and 5B can improve the fill factor by about 116% over aconventional structure thereby achieving a total fill factor of 40%.

As has been discussed above, various factors can influence depositionprecision and uniformity of organic light-emissive layers in OLEDdisplay inkjet based manufacturing techniques. Such factors include, forexample, display resolution, droplet size, target droplet area, dropletplacement error, fluid properties (e.g., surface tension, viscosity,boiling point) associated with the OLED layer material (e.g., activeOLED materials) inks, which are comprised of a combination of OLED layermaterial and one or more carrier fluids, and the velocity at which thedroplets are deposited.

In various exemplary embodiments, instead of providing multipleconfinement wells defined by confinement structures (e.g., banks)surrounding each pixel or sub-pixel, utilizing patterned regions ofdiffering surface energies (e.g., liquid-affinity and liquid-repellingregions) to define confinement regions can provide for simplification ofthe manufacturing process. The use of bank structures can includeadditional processing steps to deposit the patterned bank layer. Inaddition, when using a bank structure, it is often necessary to use apatterned deposition method, e.g. inkjet, to deposit various devicelayers in each sub-pixel that are common to all of the sub-pixels. Forexample, in various embodiments, a RGB OLED structure can have a commonHIL and a common HTL coating in each of the red, green, and bluesub-pixels, prior to providing the different red, green, and blue EMLcoatings into the corresponding color sub-pixels. When a bank structureis used, these HIT and HTL coatings are deposited using inkjet in apatternwise fashion into each well. However, in such instances, it couldsimplify the manufacturing process to use a uniform, blanket coatingtechnique to deposit those HIL and HTL layers onto all of the pixels,and then use a patternwise deposition technique for the EML. Thepresence of the bank structures can increase the difficulty in thedeposition of a uniform blanket coating. As discussed above, coatingover various structures, even over a region comprising a relativelysmall cluster of pixel electrodes, presents various challenges. Byeliminating the bank structures to define confinement wells and insteadproviding the HIL and HTL coatings using a blanket deposition technique,and then utilizing a chemical confinement mechanism definingliquid-affinity and liquid-repelling regions on the top surface of theHTL, so as to confine the EML inks used to define the sub-pixel colorlayers, the manufacturing process may be simplified.

Such liquid-affinity and liquid-repelling regions can also assist incompensating for OLED emissive ink droplet placement errors in a similarmanner to the bank structures, permitting a greater margin of acceptabledrop placement during deposition of the OLED light emissive material, asany ink droplets that may partially fall onto a boundary between liquidaffinity and liquid repelling regions can be naturally repelled from theliquid-repelling region and attracted to the liquid-affinity regionprior to drying which can make the manufacturing process more robust.Moreover, as explained in more detail below, liquid-affinity regionmargins can be employed to further accommodate potential drop placementinaccuracies. As discussed above, high precision inkjet heads used inthe conventional printing techniques can produce droplet sizes rangingfrom about 1 picoliter (pL) to about 50 picoliters (pL), with about 10pL being a relatively common size for high precision inkjet printingapplications. Droplet placement accuracy of a conventional inkjetprinting system is approximately ±10 μm.

In various exemplary embodiments, the hole conducting layer can beconfigured to create liquid-affinity regions and liquid-repellingregions such that the emissive layer confinement regions can correspondto the liquid affinity regions, with the liquid-repelling regionsfunctioning as the boundaries to contain and prevent migration ofdeposited material. The emissive layer confinement regions can bedefined to consider drying effects associated with depositing organiclight-emissive material and other active OLED materials. For example,non-uniform edges within an active region of a sub-pixel can createundesired visual artifacts. The emissive layer confinement regions cantake edge drying effects into consideration when they are defined suchthat any non-uniform edges are outside an active area of the sub-pixel.In addition, emissive layer confinement regions can be individuallyconfigured based on the organic light-emissive material and the dryingeffects associated with each material. Moreover, additional material andmanufacturing steps (e.g., formation of confinement structures) may notbe required to provide additional confinement structures to defineconfinement wells associated with each sub-pixel. Additional definitionlayers such as a pixel definition layer may in some cases be omittedbecause the emissive layer confinement regions and the subsequentdeposition of the organic light-emissive layers provide adequatedefinition for sub-pixels and pixels. However, those having ordinaryskill in the art would appreciate that pixel definition layers can beused in conjunction with the disclosed embodiments that use confinementregions defined by regions of differing surface energies.

In accordance with various exemplary embodiments described herein,manufacturing techniques can be implemented that introduce significantflexibility into the OLED manufacturing process. For example, pixellayouts and sub-pixel arrangements can include a variety of shapes,arrangements, and configurations, in light of the flexibility achievedin defining these layouts by virtue of defining liquid-affinity regionsand liquid-repelling regions. Generally, the electrical circuitry inOLED displays is isolated from the active OLED layers wherein thecircuitry is outside the confinement wells and individually addressesthe sub-pixel electrodes. However, in accordance with exemplaryembodiments described herein, active OLED layers can be deposited overelectrical circuitry within the active region of the substrate toimprove the electrical performance of the drive electronics, as well asincrease the fill factor of each pixel.

Although confinement structures to define confinement wells at thepixel/sub-pixel level within the active area of the display can beeliminated, in exemplary embodiments that define confinement regions viasurface regions of differing surface energies, a confinement structurecan nevertheless be disposed on a non-active portion of a substrate toform a single active-area display well that surrounds the entire activeregion of the substrate. For example, the confinement structure can bedisposed to surround all of the electrodes associated with the pixelswithin an image generating portion of the display. By positioning theconfinement structure outside the active pixel regions, non-uniformitiescaused at the edges of the active OLED layers in contact with orapproximate to the confinement structure can be confined outside theactive display area thereby minimizing undesired visual artifacts andreducing materials used during manufacturing by preventing material frommigrating into non-active regions of the display. Such a configurationalso can reduce precision requirements during manufacturing. Forexample, the accuracy of the deposition of the active organic materialonto a specific and precisely delineated area is no longer as criticalin the deposition of active OLED layers. When droplets are deposited toform a hole conducting layer such as a hole injection layer and/or ahole transport layer, all droplets deposited within the singleactive-area display well can amalgamate to produce a continuous layerhaving a substantially uniform thickness.

Moreover, implementing a single confinement structure in the non-activeportion of the OLED display substrate to define an active-area displaywell can improve the ease of manufacturing an OLED display. For example,inkjet nozzles can be used to deposit the active OLED layers in a highresolution display and any droplet volume variations will not have asgreat an impact on the overall display quality deposition due toaveraging that occurs from the intermixing of the drops together to forma single, continuous hole conducting film within the confinement region.For instance, a hole conducting layer, such as at least one of a holeinjection layer and a hole transport layer, can be deposited over all ofthe electrodes within the active-area display well in the active regionof the substrate. Since all drops of liquid amalgamate, deposition maybe facilitated and uniformity increased because any variation in dropvolume is insignificant and does not affect the resulting layer. Inaddition, there are no additional manufacturing steps to remove activeOLED layers from the non-active portion of the display, thereby reducingthe overall manufacturing process.

In accordance with exemplary embodiments described above, embodimentsthat use confinement regions defined by regions of differing surfaceenergies also can incorporate pixel arrangements that increase activeregion areas. For example, as above with confinement structures todefine confinement wells at the pixel/sub-pixel level, light emissivelayer confinement regions (defined by surface regions of differingsurface energies) can be defined to include an area that spans aplurality of sub-pixels associated with differing pixels such thatnon-active portions of each pixel are reduced. For instance, lightemissive layer confinement regions can be defined over a plurality ofindividually addressed sub-pixel electrodes wherein each sub-pixelelectrode can be associated with a different pixel. By increasing thearea of the defined light-emissive layer confinement regions, the fillfactor can be maximized because the ratio of the active regions to thetotal pixel area is increased. Achieving such increases in fill factorcan enable high resolution in smaller size displays as well as improvethe lifetime of the display.

Further, as described above with respect to various pixel arrangementsdescribed with reference to FIGS. 2 and 12-19, embodiment using lightemissive layer confinement regions in combination with such pixel layoutarrangements can extend the lifetime of the device. For example,sub-pixel electrode size can be based on the corresponding organic lightemissive layer wavelength emission. For instance, a sub-pixel electrodeassociated with blue light emission can be larger than a sub-pixelelectrode associated with red or green light emission. Organic layersassociated with blue light emission in OLED devices can have shortenedlifetimes relative to organic layers associated with red or green lightemission. In addition, operating OLED devices to achieve a lowerbrightness level increases the lifetime of the devices. By increasingthe emission area of the blue sub-pixel relative to the red and greensub-pixels, as well as driving the blue sub-pixel to achieve a relativebrightness while driving the red and green sub-pixels to achieve abrightness higher than the blue sub-pixel, can serve to better balancethe lifetimes of the different colored sub-pixels while still providingfor the proper overall color balance of the display. This improvedbalancing of lifetimes enables improvement in the overall lifetime ofthe display by extending the lifetime of the blue pixel.

One of ordinary skill in the art would also appreciate that alternativeconfigurations are possible to extend the lifetime of differingsub-pixel colors aside from blue. For example, a red sub-pixel couldhave a larger area than the other sub-pixels so as to extend thelifetime of the red sub-pixels. Alternatively, the green sub-pixel canhave a larger area than the other sub-pixels, so as to extend thelifetime of the green sub-pixels. Such configurations also can beapplied to OLED displays that comprise confinement structures to defineconfinement wells as well as to OLED displays that use liquid-affinityand liquid repelling regions to define confinement regions.

Referring now to FIGS. 22-39, an OLED display and exemplary steps formanufacturing the OLED display 1900 are illustrated. While the method ofmanufacturing will be discussed with reference to display 1900, anyand/or all of the steps described herein can be used in manufacturingother OLED displays, for example OLED display 1500, 1600 described withreference to FIGS. 20 and 21. The OLED display 1900 includes a substrate1902, a confinement structure 1904, and a plurality of electrodes 1906,as illustrated in the plan view of FIG. 22 and the cross-sectional viewalong line 23-23 of FIG. 22 depicted in FIG. 23.

Substrate 1902 can include an active region 1908 that is defined by thearea encompassing the electrodes 1906 (boundary shown by dashed line inFIGS. 22, 23) and a non-active region 1910. Substrate 1902 can be anyrigid or flexible and generally planar structure, and can include one ormore layers of one or more materials. Substrate 1902 can be made of, forexample, glass, polymer, metal, ceramic, or combinations thereof.

A confinement structure 1904 (e.g., a bank) can be disposed on thesubstrate 1902 such that the confinement structure 1904 defines a singleactive-area display well W. The confinement structure 1904 can be formedof various materials such as, for example, photoresist materials such asphotoimageable polymers or photosensitive silicon dielectrics. Theconfinement structure 1904 can comprise one or more organic componentsthat are, after processing, substantially inert to the corrosive actionof OLED inks, have low outgassing, have a shallow (e.g. <25 degrees)sidewall slope at the active-area display well edge, and/or have highphobicity towards one or more of the OLED inks to be deposited into theactive-area display well, and may be chosen based on the desiredapplication. Examples of suitable materials include, but are not limitedto PMMA (poly-methylmethacrylate), PMGI (poly-methylglutarimide),DNQ-Novolacs (combinations of the chemical diazonaphithoquinone withdifferent phenol formaldehyde resins), SU-8 resists (a line of widelyused, proprietary epoxy based resists manufactured by MicroChem Corp.),fluorinated variations of conventional photoresists and/or any of theaforementioned materials listed herein, and organo-silicone resists,each of which can be further combined with each other or with one ormore additives to further tune the desired characteristics of theconfinement structure 1904.

In addition, confinement structure 1904 can assist in the loading anddrying process, through appropriate geometry and surface chemistry, ofthe active OLED material to form continuous and uniform layers withinthe region of the well W bounded by the confinement structure 1904. Theconfinement structure 1904 can be a single structure or can be composedof a plurality of separate structures that form the confinementstructure 1904. Confinement structure 1904 can have any cross-sectionalshape. In addition, while confinement structure 1904 is illustrated inFIG. 22 and as having side edges perpendicular to substrate 1902,confinement structure 1904 can alternatively have angled and/or roundededges with respect to the surface of the substrate 1902.

The confinement structure 1904 can be formed using any manufacturingmethod, such as inkjet printing, nozzle printing, slit coating, spincoating, vacuum thermal evaporation, sputtering (or other physical vapordeposition method), chemical vapor deposition, etc. Any additionalpatterning not otherwise included in the deposition technique can beachieved by using shadow masking, photolithography (photoresist coating,exposure, development, and stripping), wet etching, dry etching,lift-off, etc.

The confinement structure 1904 defining active-area display well W canconfine active OLED material deposited on the substrate 1902. Forexample, confinement structure 1904 can be disposed on the non-activeportion 1910 of substrate 1902 and surround the active region 1908. Invarious exemplary embodiments, as shown in FIGS. 22-23, for example,confinement structure 1904 can be positioned outside the active area bya distance D. D can be determined based on edge drying effects and canbe selected to minimize undesired visual artifacts within the activeregion 1908 of the substrate 1902. For example, the confinementstructure 1904 can be positioned sufficiently away from any of theelectrodes 1906 to prevent any edge drying non-uniformities fromcontributing to the observed light emission from the pixels and reducingthe loading precision required to deposit active OLED material withinthe well during the manufacturing process. At the same time, it is alsodesirable to minimize the width of the inactive region outside of thedisplay area and within the area provided for making external electricalconnection to the display. Minimizing the width of the inactive regionsprovides for closer packing of multiple displays on a single substratesheet, thereby increasing manufacturing efficiency. It also provides forreducing the width of the bezel outside of the display which isdesirable for making a smaller finished display product with less wastedspace.

In an exemplary embodiment, D can range from about 10 μm to about 500μm, for example, D may be about 50 μm. Confinement structure 1904 canhave a width B ranging from about 10 μm to about 5 mm where B could beabout 20 μm. In addition, confinement structure 1904 can have a height Tranging from about 0.3 μm to about 10 μm where the height could be about1.5 μm.

A plurality of electrodes 1906 can be provided on the substrate 1902within the active region 1908 such that, when electrodes 1906 areselectively driven, light can be emitted to create an image to bedisplayed to a user. Electrodes 1906 can be disposed to define a pixelarray such that each electrode 1906 is associated with a differingsub-pixel, such as, for example, a sub-pixel associated with red lightemission, a sub-pixel associated with green light emission, a sub-pixelassociated with blue light emission, and so on. Alternatively, eachelectrode 1906 can instead be associated with a pixel comprising a redsub-pixel, a green sub-pixel, and a blue sub-pixel. Electrodes 1906 canhave any shape, arrangement, and/or configuration. For example, asillustrated in FIG. 22, electrodes 1906 can have a square shape.Alternatively, electrodes 1906 can have a rectangular, circular,chevron, hexagonal, asymmetrical, irregular curvature shape, or acombination thereof. Electrodes 1906 can have a profile such that thetop surface is substantially planar and parallel to the main surface ofthe substrate while side edges of the electrodes can be substantiallyperpendicular to or can be angled and/or rounded with respect to thesurface of the substrate 1902.

Electrodes 1906 can be transparent or reflective and can be formed of aconductive material such as metal, a mixed metal, an alloy, a metaloxide, a mixed oxide, or a combination thereof. For example, in variousexemplary embodiments, the electrodes may be made of indium-tin-oxide,magnesium silver, or aluminum.

The electrodes 1906 can be formed using any manufacturing method such asinkjet printing, nozzle printing, slit coating, spin coating, vacuumthermal evaporation, sputtering (or other physical vapor depositionmethod), chemical vapor deposition, etc. Any needed additionalpatterning not otherwise provided by the deposition technique can beachieved by using shadow masking, photolithography (photoresist coating,exposure, development, and stripping), wet etching, dry etching,lift-off, etc.

Pixels can be defined based on the pitch of the electrodes 1906. Thepitch of the electrodes can be based on the resolution of the display.For example, the smaller the pitch, the higher the display resolution.Pixels can be selected to have any type of arrangement such assymmetrical or asymmetrical to reduce undesired visual artifacts andenhance image blending to produce a continuous image.

While omitted for clarity and ease of illustration, further additionalelectrical components, circuits, and/or conductive members can bedisposed on substrate 1902. Electrical components, circuits, and/orconductive members can include driving circuitry, including but notlimited to, for example, an interconnect, bus lines, transistors, andother circuitry those having ordinary skill in the art are familiarwith. The electrical components, circuits, and/or conductive members canbe coupled to each electrode 1906 such that each electrode can beselectively addressed independently of the other electrodes. Forinstance, thin-film transistors (TFTs) (not shown) can be formed on thesubstrate 1902 before and/or after depositing any of the otherstructures such as confinement structure 1904 and/or electrodes 1906. Aswill be discussed below, active OLED layers can be deposited over anyelectrical components, circuits, and/or conductive members disposed inthe active region 1908 of the substrate 1902.

As illustrated in FIG. 24, after the electrodes 1906 and other circuitry(not shown), including e.g., TFTs, have been deposited, a first holeconducting material 1911 can be deposited within the active-area displaywell W defined by confinement structure 1904. The first hole conductingmaterial 1911 can be deposited as one or more layers of material thatfacilitates the injection of holes into an organic light-emissive layer.For example, the first hole conducting material 1911 can be deposited asa layer of a single hole conducting material such as a hole injectionmaterial. Alternatively, hole conducting material 1911 can be depositedas a plurality of differing hole conducting material, with at least onehole injection material, such as, for example,Poly(3,4-ethylenedioxythiophene:poly(styrenesulfonate) (PEDOT:PSS).

The first hole conducting material 1911 can be deposited using inkjetprinting. For example, an inkjet nozzle 1914 can direct multipledroplets 1916 of a fluid composition comprising the hole conductingmaterial within the active-area display well W. One of ordinary skill inthe art would appreciate that while a single nozzle is illustrated inFIG. 24, multiple nozzles can be implemented to deposit multipledroplets of hole conducting material simultaneously within active-areadisplay well W.

First hole conducting material 1911 can be mixed with a carrier fluid toform an inkjet composition that is formulated to provide reliable anduniform loading within the active-area display well W. The droplets forloading the first hole conducting material 1911 can be delivered to thesubstrate at high speeds from an inkjet head nozzle. The droplets 1916that form the first hole conducting layer, can be deposited within thewell W from all respective inkjet nozzles so as to amalgamate to producea continuous layer having a substantially uniform thickness, as shown inFIG. 24. The first hole conducting material 1911 can be deposited suchthat the height of the material may be greater than the height of theconfinement structure 1904 prior to drying and/or baking; althoughheights equal to or less than confinement structure 1904 also may beused.

As illustrated in FIG. 25, after the hole conducting material is loadedin the active-area display well W, display 1900 can be processed to formthe first hole conducting layer 1912. For example, the display 1900 canbe processed to allow any carrier fluid to evaporate from the first holeconducting material 1911 such as via a drying process. The process caninclude exposing substrate 1902 to heat, to vacuum, and/or ambientconditions for a period of time. Following drying, substrate 1902 may bebaked at an elevated temperature so as to treat the deposited filmmaterial, for example, to induce a chemical reaction or change in filmmorphology that is beneficial for the quality of the deposited film orfor the overall process.

The first hole conducting layer 1912 can be substantially continuouswithin the entire active-area display well W such that layer 1912 isdisposed over all surface features within the active-area display well W(e.g., electrodes 1906, circuitry (not shown), etc.) and the edges oflayer 1912 contact the confinement structure 1904 surrounding theactive-area display well W. While layer 1912 is illustrated as having aplanar top surface, hole conducting layer 1912 can alternatively followthe topography of the underlying surface features such as electrodes1906 and any circuitry (not shown) thereby producing a non-planar topsurface associated with the underlying surface features, for example ina manner similar to that described above with respect to the exemplaryembodiments of FIGS. 3-11 in which deposited layers follow surfacetopographies.

As illustrated in FIG. 26, a second hole conducting material 1917 can bedeposited within the active-area display well W defined by confinementstructure 1904 and over the first hole conducting layer 1912. The secondhole conducting material 1917 can include a hole transport material suchas, for example,N,N′-Di-((1-napthyl)-N,N′-diphenyl)-1,1′-biphenyl)-4,4′-diamine (NPB).

As with the first hole conducting material 1911, the second holeconducting material 1917 can be deposited using inkjet printing. Forexample, an inkjet nozzle 1914 can direct multiple droplets 1920 of afluid composition comprising hole conducting material within theactive-area display well W. One of ordinary skill in the art wouldappreciate that while a single nozzle is illustrated in FIG. 26,multiple nozzles can be implemented to deposit multiple droplets of holeconducting material 1920 simultaneously within active-area display wellW. In addition, while inkjet nozzle 1914 is illustrated as being thesame inkjet nozzle used to deposit the first hole conducting material1911, the inkjet nozzle used to deposit the second hole conductingmaterial 1917 can be different. Therefore, the droplet volumes of thedroplets 1920 associated with the second hole conducting material 1917can be the same or different from the droplet volumes of the first holeconducting material 1916.

Second hole conducting material 1917 can be mixed with a carrier fluidto form an inkjet composition that is formulated to provide reliable anduniform loading within the active-area display well W. The droplets forloading the second hole conducting material 1917 can be delivered to thesubstrate at high speeds from an inkjet head nozzle 1914. The droplets1920 of the second hole conducting material 1917, can be depositedwithin the well W from all respective inkjet nozzles so as to amalgamateto produce a continuous layer having a substantially uniform thickness,as shown in FIG. 26. The second hole conducting material 1917 can bedeposited such that the height of the material may be greater than theheight of the confinement structure 1904 prior to drying and/or baking;although heights equal to or less than confinement structure 1904 alsomay be used.

As illustrated in FIG. 27, after the second hole conducting material1917 is loaded in the active-area display well W, display 1900 can beprocessed to form the second dried hole conducting layer 1918. Forexample, display 1900 can be processed to allow any carrier fluid toevaporate from the second hole conducting material 1917, such as via adrying process. The process can include exposing substrate 1902 to heat,to vacuum, and/or ambient conditions for a period of time. Followingdrying, substrate 1902 may be baked at an elevated temperature so as totreat the deposited material 1917, for example, to induce a chemicalreaction or change in film morphology that is beneficial for the qualityof the deposited film or for the overall process.

The second hole conducting layer 1918 can be substantially continuouswithin the entire active-area display well W such that layer 1918 isdisposed over all surface features within the active-area display well W(e.g. electrodes 206, circuitry (not shown), the first hole conductinglayer 1912, etc.) and the edges of layer 1918 contact the confinementstructure 1904 surrounding the active-area display well W.

As illustrated in FIG. 28, the second hole conducting layer 1918 can beprocessed so as to modify a surface energy or affinity of portions ofthe second hole conducting layer 1918 to define emissive layerconfinement regions. For example, a reactive surface-active material canbe applied to the surface of layer 1918. In an exemplary embodiment, thereactive surface-active material can be exposed to radiation fromradiation source 1923 through mask 1922 where openings (not shown) inthe mask can be used to define regions of differing surface energies(e.g., liquid-affinity regions and liquid-repelling regions) withinlayer 1918, thereby resulting in emissive layer confinement regions. Inan alternative embodiment, layer 1918 can further comprise reactivesurface-active material such that emissive layer confinement regions canbe defined by exposing the second hole conducting layer 1918 usingradiation source 1923. In an exemplary embodiment, mask 1922 can bepositioned with respect to electrodes 1906 such that each opening in themask 1922 is aligned based on the width and length of each electrode1906.

The reactive surface-active (RSA) material can comprise a composition ofat least one radiation sensitive material. When the RSA material isexposed to radiation, the surface energy or affinity of the associatedlayer exposed to the radiation can be modified. For example, portions oflayer 1918 associated with the RSA material that are exposed to theradiation can have a change in at least one physical, chemical, and/orelectrical property from portions of layer 1918 not associated with theRSA material and/or not exposed to radiation from light source 1923 suchthat portions of layer 1918 exposed to radiation have a surface energyor affinity that differs from the surface energy or affinity of theportions of layer 1918 not exposed to radiation.

Radiation source 1923 can comprise any radiation source that can be usedto modify at least one physical, chemical, and/or electrical property incombination with the RSA material. For example, radiation source 1923can comprise an infrared radiation source, a visible wavelengthradiation source, an ultraviolet radiation source, a combinationthereof, etc.

The type of radiation used can depend upon the sensitivity of the RSA.The exposure can be a blanket, overall exposure, or the exposure can bepatternwise. As used herein, the term “patternwise” indicates that onlyselected portions of a material or layer are exposed. Patternwiseexposure can be achieved using any known imaging technique. In oneembodiment, the pattern is achieved by exposing through a mask. In oneembodiment, the pattern is achieved by exposing only select portionswith a laser. The time of exposure can range from seconds to minutes,depending upon the specific chemistry of the RSA used. When lasers areused, much shorter exposure times are used for each individual area,depending upon the power of the laser. The exposure step can be carriedout in air or in an inert atmosphere, depending upon the sensitivity ofthe materials.

In one embodiment, the radiation can be selected from ultra-violetradiation (10-390 nm), visible radiation (390-770 nm), infraredradiation (770-10⁶ nm), and combinations thereof, including simultaneousand serial treatments. In another embodiment, the radiation can bethermal radiation such as being carried out by heating. The temperatureand duration for the heating step is such that at least one physicalproperty of the RSA is changed, without damaging any underlying layers.In an exemplary embodiment, the heating temperature can be less than250° C. such as less than 150° C.

In an exemplary embodiment, the radiation can be ultraviolet or visibleradiation where the radiation can be applied patternwise, resulting inexposed regions of RSA and unexposed regions of RSA. After patternwiseexposure to radiation, the first layer can be treated to remove eitherthe exposed or unexposed regions of the RSA.

In another exemplary embodiment, the exposure of the RSA to radiationcan result in a change in the solubility or dispersibility of the RSA insolvents. For example, when the exposure is carried out patternwise, awet development treatment can follow the exposure step. The treatmentcan include washing with a solvent which dissolves, disperses or liftsoff one type of area. The patternwise exposure to radiation can resultin insolubilization of the exposed areas of the RSA and treatment withsolvent results in removal of the unexposed areas of the RSA.

In another exemplary embodiment, the exposure of the RSA to visible orUV radiation can result in a reaction which decreases the volatility ofthe RSA in exposed areas. When the exposure is carried out patternwise,this can be followed by a thermal development treatment. The treatmentcan involve heating to a temperature above the volatilization orsublimation temperature of the unexposed material and below thetemperature at which the material is thermally reactive. For example,for a polymerizable monomer, the material can be heated at a temperatureabove the sublimation temperature and below the thermal polymerizationtemperature. However, it is noted that RSA materials that have atemperature of thermal reactivity that is close to or below thevolatilization temperature may not be able to be developed in thismanner.

In another exemplary embodiment, the exposure of the RSA to radiationcan result in a change in the temperature at which the material melts,softens or flows. When the exposure is carried out patternwise, this canbe followed by a dry development treatment. A dry development treatmentcan include contacting an outermost surface of the element with anabsorbent surface to absorb or wick away the softer portions. This drydevelopment can be carried out at an elevated temperature, so long as itdoes not further affect the properties of the originally unexposedareas.

After the RSA material is exposed to radiation, physical properties oflayer 1918 can be modified such that exposed portions can have anincrease or decrease in surface energy from non-exposed portions. Forexample, the exposed portions can cause portions of layer 1918 to becomemore or less soluble or dispersible in a liquid material, more or lesstacky, more or less soft, more or less flowable, more or less liftable,more or less absorbable, greater or lower contact angle with respect toa particular solvent or ink, greater or lower liquid-affinity withrespect to a particular solvent or ink, etc. Any physical property oflayer 1918 can be affected.

RSA material can comprise one or more radiation-sensitive materials. Forexample, the RSA material can comprise a material having radiationpolymerizable groups such as olefins, acrylates, methacrylates, vinylethers, polyacrylates, polymethacrylates, polyketones, polysulfones,copolymers thereof and mixtures thereof. RSA material can furthercomprise two or more polymerizable groups. When the RSA materialincludes two or more polymerizable groups, crosslinking can result.

In an exemplary embodiment, the RSA material can comprise at least onereactive material and at least one radiation-sensitive material wherethe radiation-sensitive material can generate an active species thatinitiates the reaction of the reactive material when exposed toradiation. Examples of radiation-sensitive materials can include, butare not limited to, those that generate free radicals, acids, orcombinations thereof. In one embodiment, the reactive material can bepolymerizable or crosslinkable. The material polymerization orcrosslinking reaction is initiated or catalyzed by the active species.The radiation-sensitive material is generally present in amounts from0.001% to 10.0% based on the total weight of the RSA material.

In an exemplary embodiment, the reactive material of the RSA materialcan be an ethylenically unsaturated compound and the radiation-sensitivematerial of the RSA material can generate free radicals when exposed toradiation. Ethylenically unsaturated compounds can include, but are notlimited to, acrylates, methacrylates, vinyl compounds, and combinationsthereof. Any of the known classes of radiation-sensitive materials thatgenerate free radicals can be used. For example, quinones,benzophenones, benzoin ethers, aryl ketones, peroxides, biimidazoles,benzyl dimethyl ketal, hydroxyl alkyl phenyl acetophone, dialkoxyactophenone, trimethylbenzoyl phosphine oxide derivatives, aminoketones,benzoyl cyclohexanol, methyl thio phenyl morpholino ketones, morpholinophenyl amino ketones, alpha halogennoacetophenones, oxysulfonyl ketones,sulfonyl ketones, oxysulfonyl ketones, sulfonyl ketones, benzoyl oximeesters, thioxanthrones, camphorquinones, ketocoumarins, and Michler'sketone. Alternatively, the radiation sensitive material may be a mixtureof compounds, one of which provides the free radicals when caused to doso by a sensitizer activated by radiation. In one embodiment, theradiation sensitive material can be sensitive to visible or ultravioletradiation.

In an exemplary embodiment, the reactive material can undergopolymerization initiated by an acid whereby exposing theradiation-sensitive material to radiation generates the acid. Examplesof such reactive materials include, but are not limited to, epoxies.Examples of radiation-sensitive materials which generate acid, include,but are not limited to, sulfonium and iodonium salts, such asdiphenyliodonium hexafluorophosphate. In an alternative embodiment, thereactive material can comprise a phenolic resin and theradiation-sensitive material can be a diazonaphthoquinone.

The RSA material can further comprise a fluorinated material. Forexample, the RSA material can comprise an unsaturated material havingone or more fluoroalkyl groups such as a fluorinated acrylate, afluorinated ester, or a fluorinated olefin monomer. In an exemplaryembodiment, the fluoroalkyl groups have from 2-20 carbon atoms.

FIG. 29 illustrates liquid-affinity regions 1924 and liquid-repellingregions 1926 that are formed after the radiation source 1923 illuminatesthe RSA-treated second hole conducting layer 1918 through the mask 1922.FIG. 30 is an exemplary cross-section of magnified portion M illustratedin FIG. 29 and FIG. 31 is an exemplary plan view of the magnifiedportion M illustrated in FIG. 29. It is noted that the liquid-affinityregions 1924 and liquid-repelling regions 1926 are illustrated in FIG.29 as being defined within the entire thickness of the second holeconducting layer 1918. However, one of ordinary skill in the art wouldappreciate that the regions 1924 and/or 1926 can be formed in only aportion of layer 1918 for example on the top surface of layer 1918.

In an exemplary embodiment, the liquid-affinity regions 1924 can bedefined between liquid-repelling regions 1926. Liquid-repelling regionscan have a width between the liquid-affinity regions ranging from about3 μm to more than 100 μrn. The liquid-affinity regions 1924 can bedefined such that the liquid-affinity regions 1924 have a surface areaslightly larger than the surface area of each electrode 1906 and theportions of the liquid-affinity regions 1924 that are defined outsidethe active area of electrodes 1906 provide a liquid-affinity regionmargin 1930. For example, as illustrated in FIGS. 30 and 31, theliquid-affinity regions 1924 can be defined to consider drying effectsassociated with depositing organic light-emissive material such that theliquid-affinity regions 1924 can confine the organic light-emissivematerial within the liquid-affinity regions 1924. Each liquid-affinityregion 1924 can comprise an area 1928 (indicated by shaded portions inFIG. 30) associated with the active region of electrode 1906 and aliquid-affinity region margin 1930 (if present) disposed outside theactive region of electrode 1906. When organic light-emissive material isdeposited on the second hole conducting layer 1918, the organiclight-emissive material can be substantially confined within the area1928 and the liquid-affinity region margin 1930 of each liquid-affinityregion 1924. For example, when the organic light-emissive material isprocessed (e.g. dried), non-uniformities can be created at the edges ofeach organic light-emissive layer such that the non-uniformities arecontained within the liquid-affinity region margin 1930. In other words,when the organic light-emissive material is processed, the portion ofthe material within area 1928 of the liquid-affinity region 1924 has auniform top surface thereby reducing perceived visual artifacts. Theliquid-affinity regions 1924 can take edge drying effects intoconsideration when they are defined such that the distance by which anynon-uniform edges are outside of an active area of an electrode 1906 mayvary based on the edge drying effects. Such edge drying effects can alsobe taken into account when defining the shape of the liquid-affinityregion. For example, in various embodiments (not shown) the organiclight-emissive material can result in rounded edges rather than thesharp corners schematically illustrated in the figures, so as to providefor a more uniform dried film. In addition, liquid-affinity regions 1924can be flexibly configured based on the organic light-emissive materialand the drying effects associated with each material. In variousexemplary embodiments, liquid-affinity region margins 1930 (provided sothat the impact of edge drying effects on the light emitting area areminimized) of about 20 μm or less, or about 10 μm or less, or about 5 μmor less, or about 3 μm or less may be implemented. Increasing the sizeof the liquid-affinity region relative to the light emitting region canalso help compensate for alignment errors in the patternwise radiationexposure process. For example, in one exemplary embodiment, thepatternwise radiation exposure process can have an alignment accuracy ofabout 2 μm. Therefore, the increased size of the liquid affinity regioncan account for possible misalignments of about plus or minus 2 μm withrespect to the underlying light emitting region.

As discussed above, electrodes 1906 can have different shapes,arrangements, and/or configurations. For example, electrodes associatedwith blue light emission can be larger than electrodes associated withred or green emission because organic light emissive layer associatedwith blue light emission in OLED devices typically have shortenedlifetimes relative to organic light emissive layers associated with redand green light emission. In addition, operating OLED devices to achievea reduced brightness level increases the lifetime of the devices. Byincreasing the emission area of the electrodes associated with bluelight emission relative to electrodes associated with red and greenlight emissions, the electrodes associated with blue light emission canbe driven to achieve a brightness less than a brightness of theelectrodes associated with red and green light emission thereby creatinga better balance in the different organic light emissive materiallifetimes as well as providing the proper overall color balance of thedisplay. This improved balancing of lifetimes further improves theoverall lifetime of the display because the lifetime of the organiclight emissive material associated with blue emission can be extended.In addition, the liquid-affinity regions can correspond to the differentshapes, arrangements, and/or configurations of the electrodes 1906. Forinstance, in another exemplary embodiment showing a view similar to FIG.31, FIG. 32 illustrates liquid-affinity regions 1924 r, 1924 g, 1924 bcan be associated with the respective electrodes of different shapessuch that liquid-affinity region 1924 r is associated with an electrodeused to achieve red light emission, liquid-affinity region 1924 g isassociated with an electrode used to achieve green light emission, andliquid-affinity region 1924 b is associated with an electrode used toachieve blue light emission.

In an alternative embodiment illustrated in FIG. 33 which also is anexemplary embodiment of magnified portion M illustrated in FIG. 29, apixel definition layer 1938 can be deposited after electrodes 1906 aredisposed on substrate 1902. The pixel definition layers 1938 can bedeposited over a portion of electrodes 1906 and the liquid-affinityregions 1924 can be defined such that the liquid-affinity region margin1930 can overlay at least a portion of the pixel definition layers 1938.Pixel definition layers 1938 can be any physical structure used todelineate pixels within the pixel array of the active region 1908 ofdisplay 1900. Pixel definition layers 1938 can be made of anelectrically resistant material such that the definition layer 1938prevents current flow and thus can reduce unwanted visual artifacts bysubstantially preventing light emission through the edges of electrodes1906. In an exemplary embodiment, the pixel definition layers 1938 canhave a thickness within the range of about 50 nm to about 1500 nm.

As illustrated in FIG. 34, organic light-emissive material 1932 can bedeposited within the active-area display well W defined by theconfinement structure 1904. For example, organic light-emissive material1932 can be deposited using inkjet printing over the emissive layerconfinement regions patterned within the second hole conducting layer1918. Inkjet nozzle 1914 can direct droplets 1934 of ink containingorganic light-emissive material over the liquid-affinity regions 1924,for example, via a relative scanning motion of the nozzle 1914 and/orthe substrate 1902. The droplets 1934 of organic light-emissive materialcan spread evenly within the liquid-affinity regions 1924 such that thematerial pins at the edges of the liquid-affinity region 1924 (e.g.,within the liquid-affinity region margin 1930). One of ordinary skill inthe art would appreciate that while a single nozzle is discussed andshown with reference to FIG. 34, multiple nozzles can be implemented toprovide inks containing organic light-emissive material. Inks containingthe same or differing organic light-emissive material associated withdiffering light emissive colors can be deposited from multiple inkjetnozzle heads simultaneously or sequentially.

The deposited organic light-emissive material 1932 can include materialto facilitate light emission such as organic electroluminescencematerial associated with red, green, and/or blue light emission.However, organic electroluminescence material associated with otherlight emission colors also can be used such as organicelectroluminescence material associated with yellow and/or while lightemission.

The organic electroluminescence material can be mixed with a carrierfluid to form an inkjet ink that is formulated to provide reliable anduniform loading within the liquid-affinity regions 1924. The inkdeposited to produce the organic light-emissive material 1932 can bedelivered from the inkjet nozzle 1914 at high speeds onto theliquid-affinity regions 1924.

Organic light-emissive material 1932 can generally be retained withinthe surface area defined by the liquid-affinity regions 1924. Forexample, the organic light-emissive material 1932 can be loaded onto thesubstrate 1902 by depositing droplets 1934 of ink within theliquid-affinity regions 1924. Due to the surface energy characteristicsof the liquid-affinity regions 1924, the droplets of organiclight-emissive material 1932 can spread evenly within theliquid-affinity regions 1924 and pin at the edges within theliquid-affinity region margin 1930.

In various exemplary embodiments, it is contemplated that multiple inkdroplets 1934 having a volume of about 10 pL or less may be used indepositing the organic light-emissive material 1932. In variousexemplary embodiments, ink droplet volumes of about 5 pL or less, about3 pL or less, or about 2 pL or less may be used. By using the patternedliquid-affinity regions 1924 and liquid-repelling regions 1926 inaccordance with the present disclosure, relatively larger droplet volumesizes, consistent with existing inkjet nozzle technology, can beutilized. In addition, there is additional margin for droplet placementaccuracy that is created due to the liquid-affinity region margins 1930.

After the ink 1934 is loaded onto the liquid-affinity regions 1924, thedisplay 1900 can be processed to allow any carrier fluid to evaporate asillustrated in FIG. 35 to create organic light-emissive layers 1933. Thedrying process can include exposing the display to heat, to vacuum,and/or to ambient conditions for a predetermined period of time.Following drying, the display 1900 can be further baked at an elevatedtemperature so as to treat the deposited film material, for example, toinduce a chemical reaction or change in film morphology that isbeneficial for the quality of the deposited film or for the overallprocess. Any edge deformations within the organic light-emissive layers1933 during the drying and/or baking process can be contained within theliquid-affinity region margins 1930 as illustrated in and discussed withrespect to FIGS. 30 and 31.

As illustrated in FIG. 36, a second electrode layer 1936 can next bedeposited in the active-area display well W defined by confinementstructure 1904 over the dried organic light emissive layers 1933. In analternative embodiment, the second electrode layer 1936 can furtherextend beyond the confinement structure 1904. For example, the secondelectrode layer 1936 can make contact with an external conductivepathway (not illustrated) disposed on substrate 1902 to supply or drainthe current carried by the second electrode layer 1936. The secondelectrode layer 1936 can be transparent or reflective and can be formedof a conductive material such as metal, a mixed metal, an alloy, a metaloxide, a mixed oxide, or a combination thereof. For example, the secondelectrode layer 1936 can be indium tin oxide or magnesium silver. Whileillustrated in FIG. 36 as a single layer, second electrode layer 1936can have any shape, arrangement and/or configuration, includingcomprising a plurality of conductive layers. In one exemplaryembodiment, second electrode layer 1936 can be formed using a blankettechnique such that electrode 1936 results in a single electrode overthe entire active region 1908 of display 1900 (See FIGS. 22 and 23). Inan alternative embodiment, the second electrode layer 1936 can include aplurality of electrodes where one second electrode is associated with(e.g., overlays) each electrode 1906, respectively. In addition, whilesecond electrode layer 1936 is illustrated in FIG. 36 as having a planartop surface, the second electrode layer 1936 can be deposited such thatlayer 1936 reflects the underlying topography resulting in a non-planartop surface.

The second electrode layer 1936 can be formed using any manufacturingmethod such as inkjet printing, nozzle printing, slit coating, spincoating, vacuum thermal evaporation, sputtering (or other physical vapordeposition method), chemical vapor deposition, etc. Any additionalpatterning not otherwise performed during the deposition can be achievedby using shadow masking, photolithography (photoresist coating,exposure, development, and stripping), wet etching, dry etching,lift-off, etc. after deposition.

When the second electrode layer 1936 is a continuous layer spanning theactive-area display well W, the layer 1936 can blanket the topographyformed by the previously disposed layers. For example, the secondelectrode layer 1936 can contact the second hole conducting layer 1918in the liquid-repelling regions 1926 and the organic light-emissivelayers 1933 formed over the liquid-affinity regions 1924 of the secondhole conducting layer 1918.

Additional OLED layers can be deposited over the organic light-emissivelayers 1933 prior to providing the second electrode layer 1936, such asfor example, additional OLED layers may include electron transportlayers, electron injection layers, hole blocking layers, moistureprevention layers, and/or protection layers. Such additional OLED layerscan be deposited by various techniques known to those skilled in theart, such as, inkjet printing, by vacuum thermal evaporation, or byanother method, for example.

In an alternative exemplary embodiment, display 1900 can comprise asingle hole conducting layer 1913 as illustrated in FIG. 37, rather thana first hole conducting layer 1912 and a second hole conducting layer1918 as illustrated for example in FIG. 28. The liquid-affinity regions1924 can be defined in the single hole conducting layer 1913 such thatliquid-affinity region margins 1930 are defined within portions of thesingle hole conducting layer 1913 outside of the active region ofelectrodes 1906. Hole conducting layer 1913 can comprise one or morehole conducting materials. For example, hole conducting layer 1913 cancomprise a hole injection material and/or a hole transport layer.

In addition, as illustrated in FIG. 37, hole conducting layer 1913 andsecond electrode layer 1936 can conform to the underlying topographysuch that the top surface of the hole conducting layer 1913 and/or thesecond electrode layer 1936 is non-planar. For example, the depositedOLED layers may result in a surface topography that does not lie in asingle plane parallel to the substrate and across the entire active-areadisplay well W. For example, one or both of layers 1913, 1936 can benon-planar and discontinuous in a single plane of the display (whereinthe plane of the display is intended as a plane parallel to substrate1902) due to the relative depressions or protrusions associated with anysurface feature including electrodes disposed on substrate 1902. Asshown, the layers 1913, 1936 can sufficiently conform to underlyingsurface feature topographies such that a top surface of the OLED layercan have a resulting topography that follows the topography of theunderlying surface features. In other words, each deposited OLED layersufficiently conforms to all underlying layers and/or surface featuresdisposed on the substrate 1902 such that those underlying layerscontribute to the resulting non-planar top surface topography of theOLED layers after they are deposited. In this way, in a plane across theactive-area display well that is parallel to a plane of the display, adiscontinuity in layer 1913 or 1936, or both, can arise as the layer(s)rise and/or fall, relative to the plane, with the existing surfacefeatures provided from electrodes, circuitry, pixel definition layers,etc., in the active-area display well. While the layers 1913 and/or 1936need not perfectly conform to the underlying surface topography (forexample, as explained above there may be local non-uniformities inthickness around edge regions and the like), a sufficiently conformalcoating in which there are no significant build-ups or depletions ofmaterial can promote a more even, uniform, and repeatable coating. Oneof ordinary skill in the art would appreciate that the sameconsiderations described above can be applied to a hole conducting layercomprising both a hole injecting layer and a hole transporting layer,such that one or both of such layers sufficiently conform to underlyingsurface feature topographies where a top surface of either layer canhave a resulting topography that follows the topography of theunderlying surface features.

In various embodiments, confinement structure 1904 can be omitted andinstead the ink formulation and printing process can be designed suchthat liquid-repelling regions are formed in the region outside of thedisplay active area to facilitate repelling any fluids deposited withinthe non-active area of the display. For example, as illustrated in FIGS.38 and 39, first hole conducting layer 1912 and second hole conductinglayer 1918 can be deposited over electrodes 1906 and portions ofsubstrate 1902 that are in a non-active region 1910 of display 1900. Inan exemplary embodiment, layers 1912 and 1918 can be blanket coated overthe entire substrate. The second hole conducting layer 1918 can beprocessed so as to modify a surface energy or affinity of portions ofthe second hole conducting layer 1918 to define emissive layerconfinement regions. In addition, liquid-repelling portions 1925 withinthe non-active region 1910 of the display can define a confinement areaCA wherein liquid-repelling portions 1925 can surround the active area1908. As above, radiation source 1926 can provide radiation through mask1922 that impinges on a surface of the second hole conducting layer 1918treated with a RSA material. Radiation from radiation source 1926 canmodify at least one property of the RSA material to form theliquid-affinity regions 1924. The liquid-repelling portions 1925 canhave a surface energy that results in a liquid-repelling region in thoseportions. In this embodiment, there is no confinement structure aroundthe perimeter of the entire active area of the display (e.g., noactive-area display well) such that there is no structure to confine allthe printed layers to the region including and immediately around theactive area of the display. This can provide certain processingsimplifications, while at the same time potentially requiring additionallater processing steps to remove at least a portion of the material fromthe non-active display area. Organic light-emissive material 1932 can bedeposited within the liquid-affinity regions 1924. Moreover, the organiclight-emissive material 1932 can be confined substantially within theactive area 1908 of display 1900 due to the liquid-repelling portions1925.

FIG. 40 is a cross-section of magnified portion illustrated in FIG. 39and illustrates liquid-affinity regions 1924 comprising a portion 1928associated with the active area of electrode 1906 and a liquid-affinitymargin region 1930. The liquid-repelling portion 1925 of the second holeconducting layer can be spaced apart from liquid-affinity margin regions1930 associated with each electrodes 1906 in the active area 1908 thatare adjacent to the non-active area 1910. The liquid-repelling portions1925 can prevent any organic light-emissive material from migrating intothe non-active portion 1910 of display 1900.

In accordance with exemplary embodiments, the OLED devices of FIGS.22-40 can have a top emissive configuration or a bottom emissiveconfiguration. For example, in a top emissive configuration, theplurality of electrodes 1906 illustrated in FIGS. 22-40 can bereflective electrodes and the second electrode layer 1936, illustratedin FIGS. 36 and 37 can be a transparent electrode. Alternatively, in abottom emissive configuration, the plurality of electrodes 1906 can betransparent and the second electrode layer 1936 can be reflective.

In another exemplary embodiment, the OLED displays of FIGS. 22-40 can bean active-matrix OLED (AMOLED). An AMOLED display, as compared to apassive-matrix OLED (PMOLED) display, can improve display performance,but requires active drive circuitry, including thin film transistors(TFTs), on the substrate and such circuitry is not transparent. WhilePMOLED displays have some elements, such as conductive bus lines thatare not transparent, AMOLED displays have substantially more elementsthat are non-transparent. As a result, for a bottom emission AMOLEDdisplay, the fill factor may be reduced compared to a PMOLED becauselight can only be emitted through the bottom of the substrate betweenthe non-transparent circuit elements. For this reason, it may bedesirable to use a top emission configuration for AMOLED displays sincethe OLED device can be constructed on top of such active circuitelements, and the light can be emitted through the top of the OLEDdevice without concern for the opacity of the underlying elements. Ingeneral, using a top emission structure can increase the fill factor ofeach pixel defined in display 1900 because light emission is not blockedby additional non-transparent elements (e.g. TFTs, driving circuitrycomponents, etc.) deposited on the substrate 1902. However, the presentdisclosure is not limited to a top emission active-matrix OLEDconfiguration. The techniques and arrangements discussed herein can beused with any other type of displays such as bottom emission and/orpassive displays as well as those one of ordinary skill in the art wouldunderstand how to make using appropriate modifications.

The various aspects described above with reference to FIGS. 22-40 can beused for a variety of pixel and sub-pixel layouts in accordance with thepresent disclosure. One exemplary layout contemplated by the presentdisclosure is depicted in FIG. 41.

In an exemplary embodiment, emissive layer confinement regions can bedefined to include an area that spans a plurality of sub-pixels suchthat non-active portions of the pixel are reduced. For instance, asillustrated in FIG. 41, emissive layer confinement regions can bedefined over a plurality of individually addressed sub-pixel electrodeswhere each sub-pixel electrode can be associated with a different pixel.By increasing the area of the emissive layer confinement structures, thefill factor can be maximized because the ratio of the active regions tothe total pixel area is increased. Achieving such increases in fillfactor can enable high resolution in smaller size displays as well asimprove the lifetime of the display.

FIG. 41 illustrates a partial plan view of a display 2000 that includesa plurality of pixels, e.g., such as defined by dotted line boundaries2050, 2051, 2052, that when selectively driven emit light that cancreate an image to be displayed to a user. In a full color display, apixel 2050, 2051, 2052, can include a plurality of sub-pixels ofdiffering colors. For example, pixel 2050 can include a red sub-pixel R,a green sub-pixel G, and a blue sub-pixel B. Emissive layer confinementregions 2034, 2036, 2038 can be defined within a second hole conductinglayer 2026 where emissive layer confinement region 2034 can beassociated with organic light emissive material having an emission inthe red wavelength range, emissive layer confinement region 2036 can beassociated with organic light-emissive material having an emission inthe green wavelength range, and emissive layer confinement region 2036can be associated with organic light-emissive material having anemission in the blue wavelength range. Each emissive layer confinementregion 2034, 2036, 2038 can be associated with a plurality of electrodes2006, 2007, 2008, 2009, 2016, 2017, 2018, 2019, 2022, 2024. Byconfiguring the emissive layer confinement regions 2034, 2036, 2038 tobe associated with a plurality of electrodes, the overall fill factor ofthe display 2000 can be improved such as for example in high resolutiondisplays.

The exemplary layout of FIG. 41 is not intended to be limiting, ratherthere are numerous ways to implement the present disclosure. In manycases, the specific selection of a particular layout may be driven bythe constraints on the underlying layout of the electrical circuitry,the desired pixel shape such as rectangles, chevrons, circles, hexagons,triangles, and the like, and factors related to visual appearance of thedisplay (such as visual artifacts that can be observed for differentconfigurations and for different types of display content, such as text,graphics, or moving video.) Those having ordinary skill in the art wouldappreciate that a number of other layouts fall within the scope of thepresent disclosure and can be obtained through modification and based onthe principles described herein. Further, those having ordinary skill inthe art would understand that although for simplicity only the emissivelayer confinement regions are described in the description of theexemplary layout of FIG. 41, any of the features, including electrodes,surface features, circuitry, pixel definition layers, and other layersdescribed above with reference to FIGS. 22-40 can be used in combinationwith any of the pixel layouts herein.

Using various aspects in accordance with exemplary embodiments of thepresent disclosure, some exemplary dimensions and parameters could beuseful in attaining high resolution OLED displays with an increased fillfactor. Tables 9-11 include prophetic, non-limiting examples inaccordance with exemplary embodiments of the present disclosureassociated with an OLED display having a resolution of 326 ppi whereTable 9 describes a sub-pixel associated with red light-emission, Table10 describes a sub-pixel associated with green light-emission, and Table11 describes a sub-pixel associated with blue light-emission. Tables12-14 include conventional dimensions and parameters as well asprophetic, non-limiting examples in accordance with exemplaryembodiments of the present disclosure associated with a display having aresolution of 440 ppi where Table 12 describes a sub-pixel associatedwith red light-emission, Table 13 describes a sub-pixel associated withgreen light-emission, and Table 14 describes a sub-pixel associated withblue light emission.

TABLE 9 Area of Length Width Emissive For a sub-pixel associated withred of Sub- of Sub- Confinement emission in display having pixel pixelRegions resolution of 326 ppi (μm) (μm) (μm²) Sub-pixel associated withEmissive 31.5 31.5 989.5 Layer Confinement Regions as illustrated inFIG. 42 Sub-pixel associated with Emissive 28.5 28.5 809.8 LayerConfinement Regions as illustrated in FIG. 42 with definition layer asillustrated in FIG. 34

TABLE 10 Area of Length Width Emissive For a sub-pixel associated withof Sub- of Sub- Confinement green emission in display having pixel pixelRegions resolution of 326 ppi (μm) (μm) (μm²) Sub-pixel associated withEmissive 31.5 31.5 989.5 Layer Confinement Regions as illustrated inFIG. 42 Sub-pixel associated with Emissive 28.5 28.5 809.8 LayerConfinement Regions as illustrated in FIG. 42 with definition layer asillustrated in FIG. 34

TABLE 11 Area of Length Width Emissive For a sub-pixel associated withof Sub- of Sub- Confinement blue emission of a display having pixelpixel Regions resolution of 326 ppi (μm) (μm) (μm²) Sub-pixel associatedwith Emissive 30.0 65.9 1979.1 Layer Confinement Regions as illustratedin FIG. 42 Sub-pixel associated with Emissive 27.0 59.9 1619.6 LayerConfinement Regions as illustrated in FIG. 42 with definition layer asillustrated in FIG. 34

TABLE 12 Area of Length Width Emissive For a sub-pixel associated withred of Sub- of Sub- Confinement emission of a display having pixel pixelRegions resolution of 440 ppi (μm) (μm) (μm²) Sub-pixel associated withEmissive 21.4 21.4 456.4 Layer Confinement Regions as illustrated inFIG. 42 Sub-pixel associated with Emissive 18.4 18.4 337.2 LayerConfinement Regions as illustrated in FIG. 42 with definition layer asillustrated in FIG. 34

TABLE 13 Area of Length Width Emissive For a sub-pixel associated withof Sub- of Sub- Confinement green emission of a display having pixelpixel Regions resolution of 440 ppi (μm) (μm) (μm²) Sub-pixel associatedwith Emissive 21.4 21.4 456.4 Layer Confinement Regions as illustratedin FIG. 42 Sub-pixel associated with Emissive 18.4 18.4 337.2 LayerConfinement Regions as illustrated in FIG. 42 with definition layer asillustrated in FIG. 34

Embodiments disclosed herein can be used to achieve high resolution inany OLED display. Accordingly, the devices, systems, and the techniquesdescribed herein can be applied to various electronic displayapparatuses. Some non-limiting examples of such electronic displayapparatuses include television displays, video cameras, digital cameras,head mounted displays, car navigation systems, audio systems including adisplay, laptop personal computers, digital game equipment, portableinformation terminals (such as a tablet, a mobile computer, a mobiletelephone, mobile game equipment or an electronic book), image playbackdevices provided with recording medium. Exemplary embodiments of twotypes of electronic display apparatuses are illustrated in FIGS. 20 and21.

FIG. 20 illustrates a television monitor and/or a monitor of a desktoppersonal computer that incorporates any of the OLED displays accordingto the present disclosure. Monitor 1500 can include a frame 1502, asupport 1504, and a display portion 1506. The OLED display embodimentsdisclosed herein can be used as the display portion 1506. Monitor 1500can be any size display, for example up to 55″ and beyond.

FIG. 21 illustrates an exemplary embodiment of a mobile device 1600(such as a cellular phone, tablet, personal data assistant, etc.) thatincorporates any of the OLED displays according to the presentdisclosure. Mobile device 1600 can include a main body 1062, a displayportion 1604, and operation switches 1606. The OLED display embodimentsdisclosed herein can be used as the display portion 1604.

One of ordinary skill in the art would recognize that FIGS. 1-43 areschematic representations and are to be considered as representativeonly. For example, while various confinement structures 1904 and otherstructures may be illustrated as having parallel walls disposedperpendicularly to substrate and having sharp edges, those structurescan have any shape including rounded edges and/or angled walls. Inaddition, any of the layers, wells, and/or confinement regions can havenon-uniform edges such as rounded, angled, etc.

Various exemplary embodiments described above and pursuant to thepresent disclosure can permit inkjet printing of OLED displays havingrelatively high pixel density and increased fill factors by increasingthe size of the confinement wells and/or confinement areas into whichthe OLED material droplets are loaded and thereby enable the use ofattainable droplet sizes and attainable inkjet system droplet placementaccuracies, according to the present disclosure. Due to the largerconfinement wells and areas, high resolution OLED displays can bemanufactured using sufficiently large inkjet droplet volumes andattainable droplet placement accuracies, without needing to utilize toosmall of droplet volumes or excessively high droplet placementaccuracies that could pose prohibitive challenges in inkjet equipmentdesign and printing techniques. When utilizing confinement structures,without implementing a confinement well or confinement area that spans aplurality of sub-pixels according to various embodiments of the presentdisclosure, droplet size and system droplet placement errors couldsignificantly increase issues in any high resolution displaymanufactured using existing inkjet heads, as the droplets would have toolarge volumes and would overfill each sub-pixel confinement well or areaand the conventional droplet placement accuracies would lead tomisplacement of droplets either entirely or partially outside of thetarget confinement well or area, both of which would lead to undesirederrors in film deposition and corresponding visual defects in the finaldisplay appearance. The ability to achieve high pixel density withexisting droplet volumes and droplet placement accuracies enablesvarious exemplary techniques described herein to be utilized in themanufacture of displays of relatively high resolutions for manyapplications, from small size displays, such as, for example, are foundin smart phones and/or tablets, and large size displays, such as, forexample, ultra high resolution televisions.

Moreover, achieving OLED material layer(s) of substantially uniformthickness that sufficiently conform to underlying topography, inaccordance with exemplary embodiments, can promote overall OLED displayperformance and quality, and in particular can permit desirableperformance and quality to be achieved in high resolution OLED displays.

One or more of the above described embodiments also can achieve anincreased fill factor. In conventional pixel arrangements, a fill factorfor a display having a resolution in the range of 300-440 ppi has a fillfactor of less than 40%, and frequently less than 30%. In contrast,exemplary embodiments of the present disclosure may achieve a fillfactor of greater than 40%, and in some instances as high as 60%, fordisplays having a resolution in the range of 300-440 ppi. The exemplaryembodiments can be used for any pixel size and arrangement, includingpixel arrangements within high resolution displays.

The exemplary embodiments can be used with any size display and moreparticularly with small displays having a high resolution. For example,exemplary embodiments of the present disclosure can be used withdisplays having a diagonal size in the range of 3-70 inches and having aresolution greater than 100 ppi, for example, greater than 300 ppi.

Although various exemplary embodiments described contemplate utilizinginkjet printing techniques, the various pixel and sub-pixel layoutsdescribed herein and the way of producing those layouts for an OLEDdisplay can also be manufactured using other manufacturing techniquessuch as thermal evaporation, organic vapor phase deposition, and organicvapor jet printing. In exemplary embodiments, alternative organic layerpatterning can also be performed. For example, patterning methods caninclude shadow masking (in conjunction with thermal evaporation) andorganic vapor jet printing. In particular, though the pixel layoutsdescribed herein, in which multiple sub-pixels of the same color aregrouped together and/or in which the deposited OLED film layers spansubstantial topographies within the grouped sub-pixel regions, have beenconceived for inkjet printing applications, such layouts can also havebeneficial alternative application to vacuum thermal evaporationtechniques for OLED film layer deposition, in which the patterning stepis achieved using shadow masking. Such layouts as described hereinprovide for larger shadow mask holes and increased distances betweensuch holes, thereby potentially improving the overall mechanicalstability and general practicality of such shadow masks. While vacuumthermal evaporation techniques with shadow masks may not be more costlythan inkjet techniques, the use of the pixel layouts in accordance withthe present disclosure and the use of OLED film layer coatings spanningsubstantial topographies within the grouped sub-pixels associated withthe same color, also represent a potentially important application ofthe present disclosure described herein.

Various exemplary embodiments described above and pursuant to thepresent disclosure can permit inkjet printing of OLED displays havingrelatively high pixel density and increased fill factors by decreasingnon-active areas of pixels using emissive layer confinement regions toconfine inkjet drops of organic light-emissive materials by enabling theuse of conventional ink droplet sizes and convention inkjet system dropplacement accuracies, according to the present disclosure. Due to thedefined emissive layer confinement regions, high resolution OLEDdisplays can be manufactured using sufficiently large inkjet dropletvolumes and conventional drop placement accuracies, without needing toutilize too small of droplet volumes or excessively high drop placementaccuracies that could pose prohibitive challenges in inkjet equipmentdesign and printing techniques. The requirements on the droplet size andsystem drop placement error could significantly increase in any highresolution display manufactured using conventional inkjet heads. Theability to achieve high pixel density with conventional droplet volumesand conventional drop placement accuracies enables the techniquesdescribed herein to be utilized in the manufacture of displays ofrelatively high resolutions for many applications, from small sizedisplays, such as, for example, are found in smart phones and/ortablets, and large size displays, such as, for example, ultra highresolution televisions. One or more of the above described embodimentscan achieve a reduced fill factor when utilizing conventional pixelarrangements. In conventional pixel arrangements, a fill factor for adisplay having a resolution in the range of 300-440 ppi has a fillfactor of less than 40%, and frequently less than 30% due to confinementwell structures contribution to non-active pixel regions. In contrast,exemplary embodiments of the present disclosure can have a fill factorof greater than 40%, and in some instances as high as 60%, for displayshaving a resolution in the range of 300-440 ppi. The exemplaryembodiments can be used for any pixel size and arrangement and moreparticularly for pixel arrangements within high resolution displays.

The exemplary embodiments can be used with any size display and moreparticularly with small displays having a high resolution. For example,exemplary embodiments of the present disclosure can be used withdisplays in the range of 3-70 inches and having a resolution greaterthan 100 ppi and more particularly greater than 300 ppi.

Although only a few exemplary embodiments have been described in detailabove, those skilled in the art will readily appreciate that manymodifications are possible in the example embodiments without materiallydeparting from this disclosure. Accordingly, all such modifications areintended to be included within the scope of this disclosure as definedin the following claims.

It is to be understood that the various embodiments shown and describedherein are to be taken as exemplary. Elements and materials, andarrangement of those elements and materials, may be substituted forthose illustrated and described herein, and portions may be reversed,all as would be apparent to one skilled in the art after having thebenefit of the description herein. Changes may be made in the elementsdescribed herein without departing from the spirit and scope of thepresent disclosure and following claims, including their equivalents.

Those having ordinary skill in the art will recognize that variousmodifications may be made to the configuration and methodology of theexemplary embodiments disclosed herein without departing from the scopeof the present teachings.

Those having ordinary skill in the art also will appreciate that variousfeatures disclosed with respect to one exemplary embodiment herein maybe used in combination with other exemplary embodiments with appropriatemodifications, even if such combinations are not explicitly disclosedherein.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the devices, methods, andsystems of the present disclosure without departing from the scope ofthe present disclosure and appended claims. Other embodiments of thedisclosure will be apparent to those skilled in the art fromconsideration of the specification and practice of the disclosuredisclosed herein. It is intended that the specification and examples beconsidered as exemplary only.

What is claimed is:
 1. A method of manufacturing an organic light-emissive display comprising: providing a plurality of first electrodes on a substrate; depositing, via inkjet printing, a first hole conducting layer over the plurality of first electrodes; altering a liquid affinity property of selected surface portions of the first hole conducting layer to define confinement regions, wherein each of the confinement regions is associated with one or more electrodes of the plurality of first electrodes, and each of the confinement regions spans an area that is larger than an active area of each of the one or more electrodes; and depositing, via inkjet printing, an organic light emissive material over the first hole conducting layer to form an organic light emissive layer in each of the confinement regions, wherein a liquid affinity property of each of the confinement regions confines the organic light emissive layer within the confinement regions.
 2. The method of claim 1, further comprising: depositing, via inkjet printing and prior to depositing the first hole conducting layer, a second hole conducting layer that disposed between the plurality of first electrodes and the first hole conducting layer.
 3. The method of claim 1, further comprising: providing a confinement structure on the substrate, the confinement structure defining a well and surrounding the plurality of first electrodes; and depositing a second electrode over the organic light emissive layer confined in each of the confinement regions.
 4. The method of claim 3, wherein the second electrode is blanket deposited over the organic light emissive layers of all the confinement regions to form a continuous layer within the well.
 5. The method of claim 1, wherein altering the liquid affinity property of the selected surface portions of the first hole conducting layer comprises: radiating the selected surface portions of the first hole conducting layer through openings of a mask.
 6. The method of claim 1, wherein the first hole conducting layer is blanket deposited over the plurality of first electrodes to form a substantially continuous layer of material, wherein a surface of the first hole conducting layer that faces away from the substrate has a non-planar topography.
 7. The method of claim 1, further comprising: depositing a second hole conducting layer prior to depositing the first hole conducting layer, wherein the first hole conducting layer is blanket deposited over the second hole conducting layer to form a substantially continuous layer of material, and wherein a surface of the first hole conducting layer that faces away from the second hole conducting layer has a non-planar topography.
 8. The method of claim 1, wherein altering the liquid affinity property of the selected surface portions of the first hole conducting layer to define the confinement regions comprises altering the liquid affinity property such that the confinement regions exhibit a first liquid affinity and boundary regions surrounding the confinement regions exhibit a second liquid affinity different from the first liquid affinity.
 9. The method of claim 1, wherein each of the plurality of first electrodes is an individually addressed electrode that defines a sub-pixel, and wherein each said sub-pixel is associated with a differing pixel.
 10. An organic light-emissive display comprising: a substrate; a plurality of first electrodes on the substrate; a first hole conducting layer deposited over the substrate, wherein a liquid affinity property of selected surface portions of the first hole conducting layer is altered to define confinement regions, wherein each of the confinement regions corresponds to one or more electrodes of the plurality of first electrodes, and wherein each of the confinement regions spans an area that is larger than an active area of each of the one or more electrodes; and an organic light emissive layer deposited over the first hole conducting layer within each of the confinement regions.
 11. The display of claim 10, further comprising a second hole conducting layer disposed between the plurality of first electrodes and the first hole conducting layer.
 12. The display of claim 10, further comprising a second electrode disposed over the organic light emissive layer confined in each of the confinement regions.
 13. The display of claim 12, wherein the second electrode is blanket deposited over the organic light emissive layers of all of the confinement regions.
 14. The display of claim 12, further comprising: a confinement structure on the substrate, the confinement structure defining a well that surrounds the plurality of first electrodes, wherein the second electrode is a substantially continuous layer within the well.
 15. The display of claim 10, wherein the first hole conducting layer is a substantially continuous layer over the plurality of first electrodes.
 16. The display of claim 10, wherein a surface of the first hole conducting material that faces away from the substrate has a non-planar topography.
 17. The display of claim 10, further comprising a second hole conducting layer, wherein the first hole conducting layer is a substantially continuous layer over the second hole conducting layer.
 18. The display of claim 17, wherein a surface of the first hole conducting layer that faces away from the second hole conducting layer has a non-planar topography.
 19. The display of claim 10, wherein the plurality of first electrodes are arranged in an array.
 20. The display of claim 10, wherein the confinement regions exhibit a first liquid affinity, and wherein the first hole conducting layer also defines boundary regions between the confinement regions, the boundary regions exhibiting a second liquid affinity different from the first liquid affinity.
 21. The display of claim 20, wherein the second liquid affinity of the boundary regions inhibits migration of an organic light emissive material of the organic light emissive layer so as to confine the organic light emissive material within the confinement regions. 